Retort sterilization device, heating device, heat sterilization method, and heat treatment method

ABSTRACT

A retort sterilization device includes a water steam generation device for generating water steam and a heating pot, connected to the water steam generation device, for accommodating retort food. The water steam generation device includes a heat exchanger for performing heat exchange between liquid flowing in a liquid path and heating vapor flowing in the vapor path. A top end of the liquid path of the heat exchanger is connected via a water steam supply pipe to a water steam ejection section located in an internal area of the heating pot. The heat exchanger is connected to a liquid container. A bottom end of the liquid path of the heat exchanger is connected to the liquid container via a communicating tube. The liquid container is coupled to the heating pot.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a retort sterilization device, aheating device, a heat sterilization method and a heat treatment method,and specifically, to a retort sterilization device including a heatingpot for performing sterilization with heating and pressurization.

The present application claims the benefit of priority based uponJapanese Patent Application No. 2011-203092 filed on Sep. 16, 2011,Japanese Patent Application No. 2012-133245 filed on Jun. 12, 2012, andJapanese Patent Application No. 2012-133246 filed on Jun. 12, 2012. Theentirety of the contents of these applications is incorporated herein byreference.

2. Description of the Related Art

In general, a surface or inside of food has microorganisms such as mold,yeast, bacteria and the like attached or mixed thereto. When the foodcontains much moisture, such microorganisms make the food rotten. As afood preservation method for avoiding this, drying, salt preservation,low-temperature preservation and the like have been performed from olddays. Packaging in film makes it easy to completely blockmicroorganisms. Thus, heat sterilization after packaging is widely usedas an effective preservation method.

Heat sterilization is available in dry sterilization, which is performedwith heated air, and wet sterilization, which is performed with vapor orhydroheat. Wet sterilization provides a higher sterilization effectbecause of the amount of heat. A simplest method of sterilizationagainst microorganisms using wet heat is boil sterilization(sterilization in hot water), by which packaged food is put into hotwater for sterilization. However, boil sterilization has the followingdefects. When the heating time is long, the food is deteriorated byheat; and when there is a heat-resistant microorganism which does notdie even at 100° C., complete sterilization is impossible under normalpressure.

Thus, when necessary, sterilization with pressurization and heating(retort sterilization) at a temperature exceeding 100° C. is performed.When being warmed in hot water, the food cannot be heated to atemperature higher than the boiling point of water (100° C.). However,when vapor or pressurized hydroheat is used, the food can be heated to atemperature higher than 100° C. Such a method of sterilization is retortsterilization. When the food is heated at a temperature higher than 100°C., the bag packaging the food is burst during cooling because theinternal pressure of the bag becomes too high. Therefore, during thecooling, the food needs to be pressurized at a pressure higher than thepressure used for heating and the pressure needs to be adjusted. Inorder to perform retort sterilization, a device capable of adjusting thetemperature, time and pressure precisely is needed. The initial cost ishigher beyond comparison than that when a boil sterilization device isused.

For performing retort sterilization on food sealed in a bag of aheat-resistant resin film or the like, the packaging bag is heated withvapor or hydroheat in a retort pot. However, it is difficult touniformize the heating temperature in the retort pot, and thus theheating temperature may become non-uniform. Japanese Laid-Open PatentPublication No. 2008-301739 discloses a sterilization method, by whichsterilization of retort food and cooling after that are performed whilethe food is slid in a forward-backward direction and in aleftward-rightward direction.

FIG. 16 shows a sterilization device 1000 disclosed in JapaneseLaid-Open Patent Publication No. 2008-301739. In the sterilizationdevice 1000 shown in FIG. 16, a rail 220 is provided in a retort potmain body 210, and a movable table 240 is supported by the rail 220 viawheels 230. On the movable table 240, trays 260 having many bags ofretort food 250 placed thereon are stacked in multiple stages andsupported. The movable table 240 is coupled, via a shaft sealing device290 provided on the retort pot main body 210, to a driving shaft 285 ofa crank mechanism 280 drivable by a motor 270.

When the motor 270 is driven and rotated, the driving shaft 285 of thecrank mechanism 280 reciprocates the retort pot main body 210 inassociation with the rotation of the motor 270, and thus the movabletable 240 which supports the trays 260 having the retort food 250 placedthereon is slid. The retort food is sterilized and then cooled whilebeing slid, so that the food is suppressed from, for example, beingburned during the sterilization.

SUMMARY OF THE INVENTION

For sterilizing retort food having fluid food or the like sealedtherein, in Japanese Laid-Open Patent Publication No. 2008-301739, theretort food 250 is mainly slid during the sterilization to suppress thefood from being burned. However, as a result of studies, the presentinventors found the following. The temperature in the retort pot mainbody 210 is not uniform. The problem that the food may be burned duringthe sterilization is not limited to fluid food. Even non-fluid food isheated non-uniformly during the sterilization depending on the positionthereof in the retort pot main body 210.

One reason that the food is heated non-uniformly during retortsterilization is a temperature difference described below. Whenhydroheat is poured on the retort food for heating in the retort potmain body 210, there is a temperature difference between a part which isexposed to hydroheat well and a part which is not. Whenhigh-temperature, high-pressure vapor (boiler vapor) is introduced intothe retort pot main body 210 and the retort food is heated with theboiler vapor, there is a temperature difference between a part which isexposed to the boiler vapor well and a part which is not. Air remainingin the retort pot main body 210 acts as a heat insulator and causesheating non-uniformity, namely, non-uniform temperature distribution, inthe retort pot main body 210. The temperature and the pressure of theboiler vapor introduced into the retort pot main body 210 are higherthan the temperature and the pressure set in the retort pot. Therefore,the food may be heated to a higher temperature than assumed. Especiallyin a part exposed to the boiler vapor well, the problem of heatingnon-uniformity is often serious.

The air may be discharged from the retort pot main body 210 byconnecting a vacuum pump (pressure decrease pump) to the inside of theretort pot main body 210. However, use of the vacuum pump needs highfacility cost and also high running cost, which significantly raises thesterilization cost (or production cost) of retort food. As describedabove, a retort sterilization device requires high initial cost beyondcomparison than that of a boil sterilization device, and use of a vacuumpump still raises the cost. In addition, even if the air in the retortpot main body 210 can be discharged, there is still heatingnon-uniformity between a part directly exposed to the boiler vapor welland a part which is not. In a device in which hydroheat is poured on thefood, compressed air is introduced into the retort pot main body 210 toput the inside thereof into a pressurized state. Therefore, theinfluence of the air cannot be eliminated.

The heating non-uniformity involves a possibility that a low-temperaturepart of the food is not sufficiently sterilized. In addition, even ifretort sterilization is performed successfully, there is a highpossibility that the heating non-uniformity may spoil the taste of thefood.

The present invention made in light of the above-described situation,has a main object of providing a retort sterilization device, a heatingdevice, a heat sterilization method and a heat treatment method whichhave a high energy efficiency and/or are capable of suppressing heatingnon-uniformity.

A retort sterilization device according to the present inventionincludes a heating pot for accommodating retort food; and a water steamgeneration device for generating water steam. The heating pot isconnected to the water steam generation device; the water steamgeneration device has a liquid path and a vapor path independent fromeach other, and includes a heat exchanger for performing heat exchangebetween liquid flowing in the liquid path and heating vapor flowing inthe vapor path; the heating vapor from a boiler is introduced into thevapor path of the heat exchanger; a top end of the liquid path of theheat exchanger is connected via a water steam supply pipe to a watersteam ejection section located in the heating pot; the heat exchanger isconnected to a liquid container for storing the liquid to be supplied tothe heat exchanger; a bottom end of the liquid path of the heatexchanger is connected to the liquid container via a communicating tube;and the liquid container is coupled to the heating pot.

In a preferable embodiment, the liquid is stored in the liquidcontainer; and a water level of the liquid in the liquid containermatches a water level of the liquid in the liquid path of the heatexchanger.

In a preferable embodiment, the liquid container is provided with awater level adjustment member for adjusting the water level of theliquid.

In a preferable embodiment, the liquid container is connected to theheating pot via a coupling pipe.

In a preferable embodiment, the liquid container includes a liquid potmain body having a top opening in an upper part thereof and a lid forsealing the top opening of the liquid pot main body; the liquid pot mainbody is a pressure-resistant container; a bottom part of the liquid potmain body is connected to the communicating tube; and the lid isconnected to the coupling pipe.

In a preferable embodiment, the liquid container includes a liquid potmain body having a top opening in an upper part thereof; and the liquidpot main body is attached to the heating pot such that the top openingis located in the heating pot.

In a preferable embodiment, a bottom surface of the liquid pot main bodyis connected to the communicating tube.

In a preferable embodiment, a top lid which does not seal the topopening is provided at the top opening of the liquid pot main body.

In a preferable embodiment, the heating pot is cylindrical; and a plateon which a container for accommodating the retort food is to be placedis located in the heating pot.

In a preferable embodiment, the water steam ejection section is a spargepipe located so as to extend in a horizontal direction in the heatingpot.

In a preferable embodiment, a plurality of the water steam ejectionsections are located in the heating pot.

In a preferable embodiment, the water steam ejection section is locatedin a lower area in the heating pot.

In a preferable embodiment, at least two of the water steam ejectionsections are located in the lower area in the heating pot; and at leasttwo of the water steam ejection sections are located in an area abovethe lower area in the heating pot.

In a preferable embodiment, a lower part of the heating pot is connectedto a discharge pipe for discharging gas in the heating pot to outsidethe heating pot.

In a preferable embodiment, the discharge pipe is connected to avariable valve for varying an opened/closed state of the discharge pipe;and the discharge pipe is capable of discharging drip water from abottom part of the heating pot.

In a preferable embodiment, the heating pot is provided with at leastone of an air discharge valve for discharging air in the heating pot tooutside the heating pot and a proportional valve as a pressure reliefvalve for adjusting an internal pressure.

In a preferable embodiment, the air discharge valve is attached to ahighest part of the heating pot.

In a preferable embodiment, a heating device for heating the water steamis provided at a part of the water steam supply pipe connected to thewater steam ejection section.

In a preferable embodiment, the heating device is an electric heater.

In a preferable embodiment, the retort sterilization device is apressurization and heating device for circulating the water steamthrough the heat exchanger, the heating pot and the liquid container toput an internal area of the heating pot into a pressurized state.

In a preferable embodiment, the water steam generated by the water steamgeneration device is saturated water vapor having a minute pressure of0.12 MPaA or less (i.e., gauge pressure of 0.0187 MpaG or less).

In a preferable embodiment, a cooling water supply pipe is connected toa part of the water steam supply pipe such that cooling water is ejectedfrom the water steam ejection section.

In a preferable embodiment, the communicating tube for providingcommunication between the heat exchanger and the liquid container isbranched into a first path and a second path.

In a preferable embodiment, a circulation pump for circulating theliquid is located in the second path.

A heating device according to the present invention includes a heatingpot for accommodating a heating target; and a heat exchanger connectedto the heating pot. The heat exchanger has a liquid path and a vaporpath independent from each other, and performs heat exchange betweenliquid flowing in the liquid path and heating vapor flowing in the vaporpath; a top end of the liquid path of the heat exchanger is connectedvia a first pipe to an ejection section located in the heating pot; theheat exchanger is connected to a liquid container for storing the liquidto be supplied to the heat exchanger; a bottom end of the liquid path ofthe heat exchanger is connected to the liquid container via acommunicating tube; and the liquid container is coupled to the heatingpot.

In a preferable embodiment, water steam is generated from the top end ofthe liquid path of the heat exchanger by the heat exchange performed bythe heat exchanger; and the heating pot is provided with an airdischarge valve for discharging air in the heating pot to outside theheating pot when the water steam is supplied to the heating pot.

In a preferable embodiment, a lower part of the heating pot is connectedto a discharge pipe for discharging air in the heating pot to outsidethe heating pot.

In a preferable embodiment, the liquid is stored in the liquidcontainer; and a water level of the liquid in the liquid containermatches a water level of the liquid in the liquid path of the heatexchanger.

In a preferable embodiment, the liquid container includes a liquid potmain body having a top opening in an upper part thereof; and the liquidpot main body is attached to the heating pot such that the top openingis located in the heating pot.

In a preferable embodiment, the liquid in the liquid path of the heatexchanger is introduced from the top end of the liquid path into theheating pot via the first pipe; and the liquid in the heating pot isintroduced into the liquid path via the liquid pot main body and thecommunicating tube.

In a preferable embodiment, the communicating tube is connected to acirculation pump for circulating the liquid.

In a preferable embodiment, the heating target is food.

A heat sterilization method according to the present invention is amethod for performing heat sterilization in a pressurized state andincludes the steps of locating a heating target in a heating pot; andintroducing water steam into the heating pot. The water steam isgenerated by a heat exchanger; the heat exchanger, a liquid containerfor supplying liquid to the heat exchanger and the heating pot areconnected to form a sealed space; and the step of introducing the watersteam is carried out continuously to put an internal area of the heatingpot into a pressurized state.

In a preferable embodiment, the heat exchanger, the liquid container andthe heating pot are connected so as to be continuous in a loop.

In a preferable embodiment, in the step of introducing the water steam,the water steam is introduced into an area in the heating pot includinga central part and an area below the central part, and air in theheating pot is discharged from an upper part thereof.

In a preferable embodiment, in the step of introducing the water steam,air in the heating pot is discharged from a lower part thereof.

In a preferable embodiment, the heating target is at least one selectedfrom the group consisting of food packaged by a retort pouch, cannedfood and bottled food.

A heat treatment method according to the present invention is a methodfor heat-treating a heating target and includes the steps of locatingthe heating target in a heating pot; and introducing water steam intothe heating pot. The water steam is generated by a heat exchanger; theheat exchanger, a liquid container for supplying liquid to the heatexchanger and the heating pot are connected so as to be continuous in aloop; and the step of introducing the water steam is carried outcontinuously to heat an internal area of the heating pot.

In a preferable embodiment, in the step of introducing the water steam,the water steam is introduced, and also air in the heating pot isdischarged from an upper part thereof.

In a preferable embodiment, in the step of introducing the water steam,the water steam is introduced, and also air in the heating pot isdischarged from a lower part thereof.

In a preferable embodiment, in the step of introducing the water steam,the water steam is introduced into an area in the heating pot includinga central part and an area below the central part, and air in theheating pot is discharged from an upper part thereof.

In a preferable embodiment, the step of introducing the water steam intothe heating pot includes introducing overheated vapor which is generatedby heating the water steam generated by the heat exchanger.

In a preferable embodiment, the heating target is at least one selectedfrom the group consisting of retort food, fish, meat, vegetable, rootcrop, fruit, rice, bread, tea, coffee, and tsukudani.

A heat treatment method in an embodiment uses water steam, and includesthe steps of generating the water steam by a water steam generationdevice including a heat exchanger; introducing the water steam into aheating pot; and introducing liquid present in a bottom part in theheating pot into the heat exchanger.

In a preferable embodiment, in the step of heating in the heating pot,the water steam is circulated between the heat exchanger and the heatingpot to put an internal area of the heating pot into a pressurized state.

A method for producing a fish-processed product according to the presentinvention includes the step of heating fish having bones in a heatingpot. The heating pot is connected to a water steam generation device forgenerating water steam; the water steam generation device has a liquidpath and a vapor path independent from each other, and includes a heatexchanger for performing heat exchange between liquid flowing in theliquid path and heating vapor flowing in the vapor path; high-pressurevapor from a boiler is introduced into the vapor path of the heatexchanger; a top end of the liquid path of the heat exchanger isconnected via a water steam supply pipe to a water steam ejectionsection located in the heating pot; and a bottom end of the liquid pathof the heat exchanger is connected to the heating pot via acommunicating tube.

In a preferable embodiment, in the step of heating in the heating pot,the water steam is circulated between the heat exchanger and the heatingpot to put an internal area of the heating pot into a pressurized state.

In a preferable embodiment, in the step of heating in the heating pot,the bones of the fish are softened.

In a preferable embodiment, the method further includes the steps of,after the step of heating in the heating pot; kneading the fish heatedby the heating pot; and baking the kneaded fish by a high-temperaturevapor baking machine.

In a preferable embodiment, in the step of kneading the fish, aseasoning is added to the heated fish; and in the step of baking by thehigh-temperature vapor baking machine, the kneaded fish is baked in thestate of being spread to be thin.

In a preferable embodiment, the high-temperature vapor baking machineincludes a second water steam generation device for generating the watersteam; a heating device for heating the water steam to generateoverheated vapor; and a baking chamber for baking the kneaded fish withthe overheated vapor; and an ejection pipe for ejecting the overheatedvapor is located in the baking chamber.

In a preferable embodiment, the high-temperature vapor baking machinefurther includes a belt conveyor which passes through the bakingchamber; the baking chamber is an open space which is opened at anentrance and an exit for the belt conveyor; and an ejection opening ofthe ejection pipe is located above the belt conveyor.

Another heating device according to the present invention is a heatingdevice using water steam and includes a heating pot for accommodating aheating target; and a water steam generation device for generating watersteam. The heating pot is connected to the water steam generationdevice; the water steam generation device has a liquid path and a vaporpath independent from each other, and includes a heat exchanger forperforming heat exchange between liquid flowing in the liquid path andheating vapor flowing in the vapor path; high-pressure vapor from aboiler is introduced into the vapor path of the heat exchanger; a topend of the liquid path of the heat exchanger is connected via a watersteam supply pipe to a water steam ejection section located in theheating pot; and a bottom end of the liquid path of the heat exchangeris connected to the heating pot via a communicating tube.

In a preferable embodiment, the heating device circulates the watersteam between the heat exchanger and the heating pot to put an internalarea of the heating pot into a pressurized state.

In a preferable embodiment, the liquid is stored in a lower part in theheating pot; and a water level of the liquid in the heating pot matchesa water level of the liquid in the liquid path of the heat exchanger.

In a preferable embodiment, the heating pot includes a cylindrical mainbody; and includes openable/closable doors respectively at a frontopening and a rear opening of the main body.

In a preferable embodiment, the water steam generated by the water steamgeneration device is saturated water steam having a minute pressure of0.12 MPaA or less.

In a preferable embodiment, the heating target is fish.

A heat treatment method according to the present invention is a heatingmethod using water steam and includes the steps of generating the watersteam by a water steam generation device including a heat exchanger;introducing the water steam into a heating pot; and introducing liquidpresent in a bottom part in the heating pot into the heat exchanger.

In a retort sterilization device according to the present invention, thewater steam generation device connected to the heating pot includes theheat exchanger, and the top end of the liquid path of the heat exchangeris connected via the water steam supply pipe to the water steam ejectionsection located in the heating pot. The heat exchanger is connected tothe liquid container, and the bottom end of the liquid path of the heatexchanger is connected to the liquid container via the communicatingtube. The liquid container is coupled to the heating pot. Therefore, asealed space can be constructed by connecting the heat exchanger, theheating pot and the liquid container. By introducing the water steam(minute-pressure vapor) from the water steam generation device includingthe heat exchanger into the heating pot, the internal pressure of theheating pot can be gradually raised to put the internal area of theheating pot into a pressurized state. The water steam is basicallysaturated water vapor. Therefore, by introducing the water steam intothe heating pot, an atmosphere of saturated water steam containingalmost no air can be formed. Thus, heating non-uniformity caused by airacting as a heat insulator can be suppressed. As a result, a retortsterilization device having a high energy efficiency and/or capable ofsuppressing heating non-uniformity can be realized. Owing to the sealedspace provided by connecting the heat exchanger, the heating pot and theliquid container, these elements have an equal internal pressure.Therefore, the water level in the heat exchanger and the water level inthe liquid container can be matched to each other based on the Pascal'sprinciple. This stabilizes the water level in the heat exchanger, andthus water steam can be generated stably and continuously.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view showing a structure of a retort sterilizationdevice (heating device) 100 in an embodiment according to the presentinvention.

FIG. 2 is a cross-sectional view schematically showing a structure of aheating pot 50 in an embodiment according to the present invention.

FIG. 3 shows a structure of a water steam generation device 10 (heatexchanger 90) in an embodiment according to the present invention.

FIG. 4 is a schematic view showing a structure of the heat exchanger 90in an embodiment according to the present invention.

FIG. 5 is a schematic view showing a structure of a retort sterilizationdevice (heating device) 100 in an embodiment according to the presentinvention.

FIG. 6 is a schematic view showing an internal structure of the heatingpot 50 in an embodiment according to the present invention.

FIG. 7A and FIG. 7B are respectively a front view and a side viewshowing a structure of the retort sterilization device 100 in anembodiment according to the present invention.

FIG. 8 shows a structure of a retort sterilization device 100 in anembodiment according to the present invention.

FIG. 9 shows a structure of a retort sterilization device 100 in anembodiment according to the present invention.

FIG. 10 is a graph showing the temperature and the pressure in the casewhere the retort sterilization device 100 is operated.

FIG. 11 is a schematic view showing a structure of a retortsterilization device (heating device) 200 in an embodiment according tothe present invention.

FIG. 12 is a schematic view showing a structure of a retortsterilization device (heating device) 100 in an embodiment according tothe present invention.

FIG. 13 is a schematic view showing a structure of a retortsterilization device (heating device) 100 in an embodiment according tothe present invention.

FIG. 14 is a schematic view showing a structure of a retortsterilization device (heating device) 100 in an embodiment according tothe present invention.

FIG. 15 shows a structure of a production system 300 of a fish-processedproduct in an embodiment according to the present invention.

FIG. 16 is a cross-sectional view showing a structure of a conventionalretort sterilization device 1000.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present inventors studied poor energy efficiency and/or heatingnon-uniformity of a retort sterilization device for many years. Sinceconventional retort sterilization devices using high-temperaturepressurized vapor (boiler vapor) and hydroheat are completed per se, thepresent inventors considered that the defects thereof would be onlyalleviated by accumulating small improvements. However, the presentinventors found a technique unique and quite different from theconventional common knowledge, by which heating in a pressurized stateis performed using minute-pressure vapor (water steam), and thusachieved the present invention. Specifically, in order to perform retortsterilization by heating in a pressurized state using water steam(minute-pressure saturated vapor), the present inventors succeeded ingenerating a pressurized state easily in a heating pot without usingcompressed air. A retort sterilization device using boiler vapor hasproblems in terms of taste and appearance; for example, a retort odor(e.g., odor generated by denaturing of protein) may be generated, ordiscolorization (to a dull brown color) may occur, when a heating targetis heated by high-temperature boiler vapor which flows into the device.Even in a retort sterilization device in which hydroheat is poured onfood, a retort odor (e.g., odor generated by denaturing of protein) maybe generated, or discolorization (to a dull brown color) may occur,after the heating due to heating non-uniformity or the like.

Hereinafter, with reference to the drawings, embodiments of the presentinvention will be described. In the following drawings, elements havingsubstantially identical functions will be represented with identicalreference numerals for simplifying the description. The presentinvention is not limited to the following embodiments.

FIG. 1 is a schematic view showing a structure of a retort sterilizationdevice (heating device) 100 in an embodiment according to the presentinvention. The retort sterilization device 100 in this embodiment is aheating device capable of performing sterilization with pressurizationand heating (retort sterilization) on retort food sealed in a bag formedof a heat-resistant resin film or the like. The heating device 100 inthis embodiment is a device (vapor heating device) for heating a heatingtarget by use of water steam (minute-pressure saturated vapor).Especially when the heating target is food (retort food in thisexample), the heating device 100 in this embodiment is a vapor-systemfood heating device.

The retort sterilization device 100 in this embodiment includes aheating pot 50 and a water steam generation device 10 for generatingwater steam. The heating pot 50 is connected to the water steamgeneration device 10. A heat exchanger 90 is connected to a liquidcontainer 20 for storing liquid 25 to be supplied to the heat exchanger90. The liquid container 20 is coupled to the heating pot 50.

FIG. 2 is a cross-sectional view schematically showing a structure ofthe heating pot 50 in this embodiment. The heating pot 50 in thisembodiment is a retort pot (heating pot) in which retort food 70 is tobe placed. In the example shown in FIG. 2, a plate 75 on whichcontainers (trays) 72 for accommodating the retort food 70 are to beplaced is located in the heating pot 50. In this example, the retortfood 70 is accommodated in each of the trays 72, and the containers 72are stacked in multiple stages and are located in an internal area 55 ofthe heating pot 50. In the example shown here, the retort food 70 isaccommodated in the containers 72, but the food 70 may be in any otherform as long as being located in the internal area 55 of the heating pot50.

The retort food in this embodiment is food which is to be treated withheating in a pressurized state, and is, for example, food packaged in aretort pouch. A retort pouch is generally formed of a film obtained by alamination process and having a polypropylene layer on the side of thefood and a polyester (PET) or any other synthetic resin layer or analuminum foil on the outer side. The retort pouch can contain the foodinside in a sealed state by blocking air, moisture and light. Retortpouches (retort packaging containers) are available in a flat bag (flat,envelope-like bag; used for, for example, curry, “gyudon” (steamed ricetopped with stewed beef), etc.), a standing pouch (bag having anextended bottom; used for, for example, stew, etc.), and a moldedcontainer (lunch box-type plastic container having a sealing filmapplied on top thereof; used, for example, retort rice, etc.).

The “retort food” in this embodiment means food to be sterilized withpressurization and heating, and encompasses food packaged in a retortpouch, canned food, and bottled food. Food provided as retort food maybe any type of food which is suitable to be produced into retort food;for example, fish, meat, vegetables, root crops, fruits or the like. The“retort food” in this embodiment is not limited to food for humans, andmay be food for pets or animal retort food. “Retort sterilization”(heating in a pressurized state) for producing retort food is notlimited to being used for the purpose of heat sterilization treatment,and may be used for the purpose of softening the food. Representativeexamples of the retort food include curry (retort curry), stew, soup,porridge, pasta sauce, ingredients of “donburi” (ingredients of toppingsof boiled rice), rice (retort rice), hamburger steak, meat ball, and thelike.

Retort treatment (retort sterilization) is, on principle, sterilizationperformed in the state where a central part of the food in the containeris pressurized and heated at 120° C. for 4 minutes or by use of anequivalent amount of heat (the temperature and time are adjusted inaccordance with the type of food). This treatment can annihilate sporebacteria and also is considered to eliminate the botulinum bacteria,which are most heat-resistant among general food-poisoning bacteria. Inthe food industry, the numerical value which represents theeffectiveness of sterilization is F value (F value=1 at 120° C. for 1minute). Usually, sterilization of an F value of 5 about to 10 isperformed.

The heating pot 50 in this embodiment is a pressure-resistant heatingcontainer and is cylindrical. The heating pot 50 in this embodiment isformed of, for example, a stainless steel material. Since the heatingpot 50 is cylindrical, a structure strong against the pressure isprovided. However, the heating pot 50 is not limited to beingcylindrical, and may be of any other shape as long as acting as a retortpot. The heating pot 50 is preferably cylindrical because a heating potof any other shape (e.g., shape having a quadrangular cross-section) isheavier than a cylindrical heating pot. Herein, the term “cylindrical”is not limited to a precisely cylindrical shape in a geometric sense. Ashape having a slightly deformed circular cross-section (e.g.,elliptical, egg-shaped), namely, a substantially cylindrical shape, isusable.

The water steam generation device 10 in this embodiment includes theheat exchanger 90. The structure of the heat exchanger 90 in thisembodiment is shown in FIG. 3 and FIG. 4. FIG. 3 shows a cross-sectionalstructure of the heat exchanger 90 together with a boiler 94. FIG. 4 isa perspective view schematically showing an internal structure of theheat exchanger 90.

The heat exchanger 90 in this embodiment includes a liquid path 91 and avapor path 92 independent from each other. Heat is exchanged betweenliquid (in this example, water) flowing in the liquid path 91 andheating vapor (in this example, steam vapor) flowing in the vapor path92.

As shown in FIG. 3, the heating vapor from the boiler 94 (boiler vaporor high-pressure vapor) is introduced into the vapor path 92 of the heatexchanger 90. Specifically, the high-pressure vapor from the boiler 94is introduced into the vapor path 92 of the heat exchanger 90 via aboiler pipe 82. In the heat exchanger 90, the heat of the heating vaporflowing in the vapor path 92 is transferred to the liquid present in theliquid path 91 and thus heat is exchanged. In the heat exchanger 90, theheat is exchanged when the heating vapor (thermal medium) and the liquid(medium to be heat-exchanged) cross each other in a non-contact manner.Thus, water is boiled and water steam (minute-pressure saturated vapor)15 is generated. The heating vapor after the heat exchange in the heatexchanger 90 is discharged via an exhaust steam pipe 84.

As shown in FIG. 4, the heat exchanger 90 in this embodiment includes aplurality of liquid paths 91 located in an outer casing 93. In thisembodiment, the outer casing 93 is generally cylindrical, and the liquidpaths 91 are formed of heat transmission pipes. The heat transmissionpipes forming the liquid paths 91 are formed of a material fortransferring the heat of the thermal medium (steam) to the heat exchangetarget (in this example, water), and are formed of, for example, metalpipes (e.g., stainless steel). The liquid paths (heat transmissionpipes) 91 extend in a longitudinal direction (axial direction) of thecylindrical outer casing 93. In this embodiment, the liquid paths 91extend in the axial direction and are located parallel to each otherwith an interval in a circumferential direction of the cylindrical outercasing 93. A space between the liquid paths (heat transmission pipes) 91acts as the vapor path 92 through which the thermal medium (steam) 16passes. The water steam 15 is generated and transferred from tip ends 91a of the liquid paths 91 of the heat exchanger 90.

As shown in FIG. 1, the water steam generation device 10 including theheat exchanger 90 is connected via a water steam supply pipe 12 to awater steam ejection section 52 located in the internal area 55 of theheating pot 50. Therefore, the water steam 15 generated from top ends 91a of the liquid paths 91 of the heat exchanger 90 is transferred throughthe water steam supply pipe 12, is introduced into the internal area 55of the heating pot 50, is ejected from the water steam ejection section52, and is released into the internal area 55 of the heating pot 50(arrow 53).

In this embodiment, at least one water steam ejection section 52 islocated in the internal area 55 of heating pot 50. In the structure ofthis embodiment, a plurality of water steam ejection sections 52 (52A,52B) are located in the internal area 55 of the heating pot 50. Thewater steam ejection sections 52 in this embodiment are each a spargepipe having a plurality of ejection openings. In the example shown here,the water steam ejection sections 52 are located so as to extend in ahorizontal direction in the internal area 55 of the heating pot 50. Inthis example, the water steam ejection sections 52 (sparge pipes) arelocated in a longitudinal direction of the cylindrical heating pot 50.

In the structure shown in FIG. 2, at least one of the water steamejection sections 52 (52B) in this embodiment is located in a lower areaof the internal area 55 of the heating pot 50. In the example shownhere, two sparge pipes 52B are located in the lower area of the internalarea 55 of the heating pot 50. In this embodiment, the “lower area” ofthe internal area 55 of the heating pot 50 refers to an area close to abottom surface of the internal area 55 of the heating pot 50. In theexample shown in FIG. 2, the “lower area” is an area below the plate 75.Also in the example shown in FIG. 2, the water steam ejection sections52 (52A) are located above the lower area in the heating pot 50. In thisexample, the water steam ejection sections 52 (52A) are located in acentral area of the heating pot 50 (a horizontal plane passing thecenter of the cylindrical heating pot 50 or in the vicinity thereof). Inthe example shown here, two lower sparge pipes 52B and two centralsparge pipes 52A are located in the internal area 55 of the heating pot50. The two sparge pipes 52A are located in left-right symmetry to eachother, and the lower sparge pipes 52B are also located in left-rightsymmetry to each other. It is possible to locate one or a plurality of(e.g., two) water steam ejection sections (sparge pipes) 52 in an upperarea in the heating pot 50 (area close to a top surface of the internalarea 55 of the heating pot 50). Namely, according to the structure ofthis embodiment, it is possible to locate a plurality of water steamejection sections (sparge pipes) 52 in the entire internal area 55,namely, in the upper, lower, left and right parts therein.

Bottom ends 91 b of the liquid paths 91 of the heat exchanger 90 areconnected to the liquid container 20 via a communicating tube 30. Morespecifically, one end 30 a of the communicating tube 30 is connected tothe liquid container 20, and the other end 30 b of the communicatingtube 30 is connected to the heat exchanger (especially, the bottom ends91 b of the liquid paths 91). Therefore, the liquid (water) 25 in theliquid container 20 can be transferred to the communicating tube 30.Then, the water steam is generated from the liquid paths 91 of the heatexchanger 90 and the water level in the liquid paths 91 of the heatexchanger 90 is lowered. In accordance with this, and so as tocompensate for this, the liquid in the communicating tube 30 istransferred toward the bottom ends 91 b of the liquid paths 91 of theheat exchanger 90.

In the structure shown in FIG. 1, the liquid container 20 includes aliquid pot main body 21 having an opening 21 a in an upper part thereofand a lid 22 for sealing the opening 21 a of the liquid pot main body21. The liquid pot main body 21 is a pressure-resistant container andcan withstand a predetermined pressure during the operation. A bottompart of the liquid pot main body 21 is connected to the communicatingtube 30. The lid 22 for closing the opening 21 a in the upper part ofthe liquid pot main body 21 is connected to a coupling pipe 28. One end28 a of the coupling pipe 28 is located in the liquid container 20, andthe other end 28 b of the coupling pipe 28 is located in the internalarea 55 of the heating pot 50.

In the structure shown in FIG. 1, a lower part of the heating pot 50 isconnected to a discharge pipe 69. The discharge pipe 69 in thisembodiment can discharge drip water (obtained as a result of the vaporbeing deteriorated, liquid generated from the heating target) stored inthe bottom part in the heating pot 50. The discharge pipe 69 is openedor closed by a variable valve 69 a. The discharge pipe 69 (and thevariable valve 69a) in this embodiment can be used to discharge gas (airand/or vapor) in the heating pot 50 to the outside. The discharge pipe69 and the variable valve 69 a can adjust the internal pressure of theheating pot 50.

In the structure shown in FIG. 1, the liquid container 20 is sealed bythe liquid pot main body 21 and the lid 22. Alternatively, thecommunicating tube 30 and the coupling pipe 28 may be connected to eachother in the liquid container 20 of an integrated form without providingthe lid 22. Still alternatively, the lid 22 may be attached to a part,other than the top surface (for example, a side surface), of the liquidpot main body 21 included in the liquid container 20.

In the retort sterilization device 100 in this embodiment, the liquidcontainer 20 is connected to the heating pot 50 via the coupling pipe28. The liquid path 91 of the heat exchanger 90 is connected to theheating pot 50 via the water steam supply pipe 12. The liquid path 91 ofthe heat exchanger 90 is connected to the liquid container 20 via thecommunicating tube 30. Therefore, a sealed space can be constructed byconnecting the heat exchanger 90, the heating pot 50 and the liquidcontainer 20. By introducing the water steam (minute-pressure vapor) 15generated by the water steam generation device 10 including the heatexchanger 90 into the heating pot 50, the pressure of the internal area55 of the heating pot 50 can be gradually raised with the introducedwater steam 53 to realize a pressurized state.

In the sealed structure having the sealed space, the pressure is equalat any position because of the Pascal's principle. Therefore, as long asthe heat exchanger 90, the heating pot 50, the liquid container 20 andthe pipes connecting these have a pressure-resistant structure, theinternal pressure of the sealed structure is gradually raised whilebeing equal.

This will be described in more detail. Even if the vapor (water steam)generated from the heat exchanger 90 is of a minute pressure, a sealedspace such as a balloon, a tire or the like can be put into apressurized state by continuously supplying gas to the sealed space.When the pressure of the pressurized state is entirely insynchronization, the pressure is gradually raised, and as a result, apressure higher than that of the introduced vapor (water steam) can beachieved. Namely, since the Pascal's principle works in a sealedstructure, when the internal pressure of the heating pot 50 is slightlyraised by the introduction of minute-pressure water steam, the samelevel of pressure is generated also in the heat exchanger 90. As aresult, as the minute-pressure water steam is gradually introduced, theinternal pressure of the heat exchanger 90 is raised along with theinternal pressure of the heating pot 50 (and of the liquid container20). As a result, even if the pressure of the water steam generated fromthe heat exchanger 90 is about 0.12 MPaA or less (i.e., gauge pressureof 0.0187 MpaG or less), the internal pressure of the heating pot 50 canbe made higher than 0.12 MPaA. Specifically, the internal pressure ofthe heating pot 50 can be made in the range of an absolute pressure of0.12 MPaA or a pressure close thereto to about 0.2 MPaA (or 0.3 MPaA).The temperature can be raised to about 120° C., which is up to about 90%(about 80 to 90%) of the temperature of the thermal source for heatexchange. Typically, water steam (minute-pressure vapor) having apressure of 0.13 MPaA or less (in one example, 0.105 to 0.12 MPaA) isused to put the internal area 55of the heating pot 50 into a pressurizedstate in which retort sterilization can be performed (e.g., about 0.2MPaA).

In addition, water steam is basically saturated water vapor. Therefore,by introducing the water steam into the heating pot, an atmosphere ofsaturated water vapor containing almost no air can be formed. Thus,heating non-uniformity caused by air acting as a heat insulator can besuppressed. As a result, a retort sterilization device which has a highenergy efficiency and/or can suppress heating non-uniformity can berealized. Boiler vapor contains impurities, but water steam does notcontain impurities. On this point also, the water steam is advantageous.

In the sealed space formed of the heat exchanger 90, the heating pot 50and the liquid container 20, the pressure is substantially equal at anyposition. Therefore, the water level (WL1) in the liquid container 20can be matched to the water level (WL2) in the liquid path 91 of theheat exchanger 90 via the communicating tube 30 based on the

Pascal's principle. Specifically, in a pre-pressurization state, thewater level (WL1) in the liquid container 20 can be matched to the waterlevel (WL2) in the liquid path 91 of the heat exchanger 90 owing to theatmospheric pressure based on the Pascal's principle. In a pressurizedstate, the water level (WL1) in the liquid container 20 can be matchedto the water level (WL2) in the liquid path 91 of the heat exchanger 90owing to the internal pressure of the sealed space, again based on thePascal's principle.

Since the water level (WL2) in the liquid path 91 of the heat exchanger90 can be controlled simply and stably, vapor (water steam) can beintroduced stably. Introduction of high-temperature, high-pressureboiler vapor is difficult to be controlled precisely. By contrast,according to the retort sterilization device 100 in this embodiment,vapor introduction can be controlled precisely in accordance with thecontrol procedure. One reason for this is that the minute-pressure watervapor (water steam) has a low flow rate and thus is easily controllable.As a result, according to the retort sterilization device 100 in thisembodiment, a sterilization and/or heating process can be allowed toproceed precisely, stably and simply.

In the structure shown in FIG. 1, the liquid container 20 is providedwith a water level adjustment member 23 for adjusting the water level(WL1) of the liquid 25. The water level adjustment member 23 is formedof, for example, a water level indicator (e.g., floating sphere). Theliquid container 20 is connected to a pipe (e.g., water pipe) 26 forsupplying liquid (water). According to the structure of this embodiment,water can be supplied via the pipe (e.g., pipe having a pressure higherthan the internal pressure; typically, water pipe) 26 based on the waterlevel WL1 indicated by the water adjustment member (water levelindicator) 23. The water adjustment member 23 is not limited to a simplewater level indicator (e.g., floating sphere), and may be anelectronically controllable device which can adjust the water level WL1to a prescribed or constant level.

As described above, according to the retort sterilization device 100 inthis embodiment, boiler vapor (pressurized vapor for heating) from theboiler 94 is not introduced as it is into the internal area 55 of theheating pot 50, but the water steam 15 from the water steam generationdevice 10 is introduced into the internal area 55 of the heating pot 50.The water steam generation device 10 generates the water steam(saturated water vapor) 15 having a minute pressure (e.g., 0.12 MPaA orless). Owing to having such a minute pressure, the water steam 15 istransferred slowly in the water steam supply pipe 12 and introduced intothe internal area 55 of the heating pot 50. Herein, the “water steam”refers to minute-pressure vapor, not high-pressure vapor such as boilervapor. In other words, the “water steam” in this embodiment is nothigh-temperature, high-pressure steam vapor, but is minute-pressurevapor (e.g., vapor having a pressure of 0.12 MPaA or less). Herein, the“water steam” is characterized in being minute-pressure vapor, and maybe any vapor which rises from boiled water (water vapor). The “watersteam” is not limited to being in a state of small water drops whichappear like a white smoke. Namely, the “water steam” may be in a statelike a white smoke or may be transparent.

According to the technological common knowledge, in order to realize ahigh-temperature, high-pressure heating environment in a heating pot,high-pressure gas (vapor, air) is introduced into the heating pot torealize a high-temperature, high-pressure state. The higher the pressureis, the easier it is to realize a high-temperature heating environment.Against such an assumption, the present inventors continuouslyintroduces the water steam 15, which is minute-pressure vapor, into theheating pot 50, so that the internal area 55 of the heating pot 50 isput into a pressurized state. Namely, the present inventors constructs apressurized state in the heating pot 50 in an approach different fromthe technological common knowledge in the art.

According to the heating device 100 in this embodiment, the water steam15 having a pressure of 0.11 MPaA or 0.12 MPaA is continuouslyintroduced, and thus the internal area 55 of the heating pot 50 can beprovided with a pressure of, for example, 0.15 MPaA to 0.25 MPaA (in oneexample, 0.15 MPaA (111° C.)), 0.20 MPaA (120° C.) or 0.30 MPaA (133°C.). Since the liquid is automatically supplied to the liquid path 91 ofthe heat exchanger 90 via the communicating tube 30, the water steam 15can be continuously introduced into the heating pot 50 by the heatexchange performed by the heat exchanger 90. In one example, boilervapor having a pressure of 0.30 MPaA (133° C.) is used to generate watersteam (clean steam) 15 having a pressure of 0.12 MPaA (104° C.) by useof the heat exchanger 90 (in other words, the water steam generationdevice 10 of a vapor indirect heating system) and to raise the pressureand the temperature of the water steam 15 by the above-describedmechanism (synchronous pressure raising method), so that the internalarea 55 of the heating pot 50 is put into a pressurized state with thewater steam 15. Specifically, the pressure of the internal area 55 ofthe heating pot 50 can be raised to, for example, 0.20 MPaA (120° C.) bythe pressure and temperature rise performed with the water steam 15provided by the heat exchanger 90.

In the heating pot 50 of the heating device 100 in this embodiment,heating by vapor (heating by the water steam 15) was performed at aheating temperature of 110 to 120° C. and a pressure of 0.14 MPaA to0.20 MPaA for, for example, 20 to 40 minutes. As a result, retortsterilization of an F value of 6 was performed on retort food. Theheating temperature and the heating time (or pressure) are not limitedto these, and may be selected appropriately. For example, retortsterilization may be performed in a shorter time than 20 minutes or alonger time than 40 minutes depending on the conditions. Specifically,the heating time varies in accordance with the specific heat, size orthe like of the heating target. Therefore, an appropriate heating timemay be selected in accordance with the target.

Food provided as a product by a retort production method is often not astasty as usual cooked food, which is produced by a method other than theretort production method. A conceivable reason for this is that the mainobject of the retort production method is to sterilize at a hightemperature in a pressurized state (retort sterilization) (namely,sterilization is the main object) but is not to improve the state of theheated food. A treatment performed by a conventional retortsterilization device heats the food at a high temperature in apressurized state, which often results in generation of a retort odor(e.g., odor generated by denaturing of protein) after the heating. Inaddition, when boiler vapor (about 130 to 150° C.) is directlyintroduced into the heating pot, there is a high possibility thatnon-uniformity is caused in raising the temperature in the heating pot.In the case where pressurized air (compressed air) is used for raisingthe pressure, heating non-uniformity is caused also by an influence ofintroduction of pressurized air acting as a heat insulator.

By contrast, according to the retort sterilization device (heattreatment method) in this embodiment, water steam can be continuouslyintroduced into the heating pot 50 by use of the heat exchanger 90. Bygradually raising the pressure and the temperature through theintroduction of the water steam 15, the temperature in the heating pot50 in this embodiment and the temperature of the retort food 70 in theheating pot 50 can be raised in a matched state. (Note that the coretemperature of the retort food 70 is raised in a delayed manner.) As aresult, an effect provided by the stable temperature rise of the food70, an effect provided by the uniform heating environment in the heatingpot 50 (reduction of the heating non-uniformity), an effect provided bythe clean vapor (water steam) with no use of boiler vapor, an effectprovided by the heating environment in a low air state (high thermalconductivity owing to a small amount of air), an effect provided by theheating environment having high concentration water vapor similar to thestate inside a basket steamer, and the like are obtained. The specificheat of saturated water vapor is higher than the specific heat of dryair. Therefore, the heating environment having high concentration watervapor containing substantially no air is preferable for heating food(especially, retort sterilization).

In a structure in which the water steam ejection section 52 is locatedin the lower area (or the central area) of the internal area 55 of theheating pot 50, the following advantages are provided. When the watersteam ejection section 52 is located in the lower area (or the centralarea) of the internal area 55 of the heating pot 50 in a structure inwhich an air discharge valve for discharging air in the internal area 55of the heating pot 50 to the outside is located in the upper area in theheating pot 50, the water steam 53 is transferred to the lower area ofthe internal area 55 of the heating pot 50 during an initial period ofthe introduction of the water steam 53, because the water steam 53formed of water vapor has a higher specific gravity than that of theair. As the reaction to the introduction of the water steam 53, the airinitially present in the internal area 55 of the heating pot 50 isdischarged via the air discharge valve provided in, for example, theupper area in the heating pot 50. Next, as the water steam 53 isintroduced, the water steam 53 fills the heating pot 50 from arelatively lower area to a relatively upper area thereof in terms of theconcentration of the water steam 53. As the water steam 53 isintroduced, the air in the heating pot 50 is discharged via the airdischarge valve.

In the case where boiler vapor (about 130 to 150° C.) is directlyintroduced into the heating pot 50, the air in the heating pot 50 cannotbe discharged for the following reasons. The high-temperature,high-pressure boiler vapor introduced into the heating pot 50 istransferred at quite a high rate in the heating pot 50, and therefore itis dangerous to open the heating pot 50 with an electromagnetic valve.Even if the heating pot 50 is opened, it is difficult to discharge onlythe air, and both of the air and the boiler vapor are dischargedoutside. There is another problem that since the internal pressurerapidly becomes high due to the volume expansion of air, it is difficultto put the boiler vapor into the heating pot 50. Even if an airdischarge valve is provided in the heating pot 50, the air cannot bedischarged with priority at the time of introduction of the boiler vaporbecause the boiler vapor is transferred while being diffused at a highrate in the heating pot 50 and thus is mixed with the air. Therefore,with the method of directly introducing boiler vapor into the heatingpot, the air needs to be discharged by a vacuum pump before the boilervapor is introduced, in order to realize appropriate heating control.Use of a vacuum pump requires facility cost and energy cost. Inaddition, it loses a lot of energy to repeat the steps of putting theinternal area 55 of the heating pot 50 into a vacuum state by the vacuumpump, raising the internal pressure of the heating pot 50 with theboiler vapor, returning the internal pressure to normal pressure forremoving the boiler vapor, and then putting the internal area 55 of theheating pot 50 into a vacuum state again for another cycle of heating.The structure of the retort sterilization device 100 in this embodimentcan solve such a poor energy efficiency. It is convenient that the airdischarge valve attached to the heating pot 50 in this embodiment has astructure in which air can be naturally discharged by a pressuredifference between the inside and the outside of the heating pot 50.

In the case where the water steam ejection section 52 is located in thecentral area in the heating pot 50, as well as in the case where thewater steam ejection section 52 is located in the lower area in theheating pot 50, the water steam 53 is transferred to the lower area inthe heating pot 50 because of the specific gravity difference betweenthe water steam 53 and air. Therefore, an effect that the air isdischarged at the time of introduction of the water steam 53 isprovided. In the case where the water steam ejection section 52 islocated in the central area in the heating pot 50, it is easy to spraythe water steam 53 to the food (retort food) 70 which is put in thecentral part (central position) in the heating pot 50. This provides aneffect in terms of the heating efficiency and the sterilizationefficiency. As shown in FIG. 2, in the case where the water steamejection sections 52 are located in both of the lower area and thecentral area in the heating pot 50, both of the effect of dischargingthe air at the time of introduction of the water steam 53 and the effectof uniformizing the heating temperature in the heating pot 50 can beprovided.

The water steam ejection section 52 may be provided in the upper area inthe heating pot 50. In the case where the water steam ejection section52 is provided in the central area and/or the upper area in the heatingpot 50, the water steam 53 is transferred to the lower area in theheating pot 50 because of the specific gravity thereof. Therefore, thedischarge pipe 69 provided on the lower part of the heating pot 50 canbe opened so as to discharge the air along with the flow of thetransferring water steam 53.

In the retort sterilization device 100 shown in FIG. 1, the liquidcontainer 20 is located outside the heating pot 50. The retortsterilization device 100 is not limited to this, and may have anotherstructure. Specifically, as shown in FIG. 5, the liquid container 20 maybe attached to the heating pot 50.

In the retort sterilization device 100 shown in FIG. 5, the liquidcontainer 20 includes a liquid pot main body 21 having a top opening 21a. The liquid pot main body 21 is attached to the heating pot 50 suchthat the top opening 21 a of the liquid pot main body 21 is located inthe internal area 55 of the heating pot 50. Namely, the liquid container20 is attached to the lower part (bottom surface) of the heating pot 50,and the top opening 21 a of the liquid pot main body 21 is exposed tothe internal area 55 of the heating pot 50.

In the structure shown in FIG. 5, a bottom surface 21 b of the liquidpot main body 21 is connected to the communicating tube 30, and thecommunicating tube 30 is connected to the heat exchanger 90 (especially,the bottom end 91 b of the liquid path 91 of the heat exchanger 90). Insuch a structure in which the liquid container 20 is attached to theheating pot 50 also, the heat exchanger 90, the heating pot 50, and theliquid container 20 are connected to each other to form a sealed space.By introducing the water steam 15 (minute-pressure vapor) 15 from thewater steam generation device 10 including the heat exchanger 90 intothe heating pot 50, the pressure of the internal area 55 of the heatingpot 50 can be gradually raised with the introduced water steam 53 torealize a pressurized state.

According to the retort sterilization device 100 shown in FIG. 5 also,the water level (WL1) in the liquid container 20 (liquid pot main body21) and the water level (WL2) in the heat exchanger 90 (liquid path 91of the heat exchanger 90) can be matched to each other by the internalpressure of the sealed space being equal, namely, based on the Pascal'sprinciple. Specifically, as the amount of liquid (water) 25 b in theliquid path 91 of the heat exchanger 90 is decreased along with thegeneration of the water steam 15, liquid (water) 25 a in the liquidcontainer 20 is automatically supplied to the liquid path 91 of the heatexchanger 90 via the communicating tube 30 (liquid 25 c). Therefore, thewater levels of the liquid 25 (WL1 and WL2) can be adjusted to be equalto each other.

According to the structure shown in FIG. 5, the liquid container 20(liquid pot main body 21) may be connected to the liquid supply pipe(water pipe) 26 for supplying tap water or the like. Water can also besupplied via a pipe (e.g., pipe having a pressure higher than theinternal pressure; typically, water pipe 26) based on the water levelWL1 indicated by the water level adjustment member (water levelindicator) 23. The water adjustment member 23 is not limited to a simplewater level indicator (e.g., floating sphere), and may be anelectronically controllable device which can adjust the water level WL1to a prescribed or constant level.

According to the retort sterilization device 100 in this example, theliquid generated in the heating pot 50 (encompassing condensed watersteam) reaches the liquid pot main body 21. The liquid 25 (25 a) in theliquid pot main body 21 can be used as the liquid 25 (25 b) to beprovided to the heat exchanger 90. Namely, according to the retortsterilization device 100 shown in FIG. 5, the water steam 15 iscirculated between the heat exchanger 90 and the heating pot 50 (moreaccurately, the water steam 15 and the liquid in the communicating tube30 are circulated), so that the internal area 55 of the heating pot 50can be put into a pressurized state. By this circulation heating system,the water steam 15 is made reusable. Therefore, a high efficiency retortsterilization device with less waste of the liquid (water) can berealized. In the retort sterilization device 100 in this embodiment, thevapor may be discharged outside via the discharge pipe 69 equipped withthe variable valve 69 a, so that the heating pot 50 is driven while thepressure therein is adjusted, in addition to the liquid being positivelyreused.

The liquid 25 (25 a) generated in the heating pot 50 and reaching theliquid pot main body 21 is warm water. Therefore, as compared with thecase where cooling water is heated by the heat exchanger 90, the energyefficiency can be improved. Namely, according to the retortsterilization device 100 in this example, thermal energy which would beotherwise disposed of can be reused. In addition, according to thestructure in this example, drop waste liquid generated in the internalarea 55 of the heating pot 50 can also be treated simply. Thus,multi-faceted advantages are provided.

Now, with reference to FIG. 6 through FIG. 10, the structure of theretort sterilization device 100 in this embodiment will be described inmore detail. The retort sterilization device 100 shown in FIG. 6 throughFIG. 10 is of a preferable example embodying the retort sterilizationdevice 100 in this embodiment, and the retort sterilization device 100in this embodiment is not limited to such a structural example.

FIG. 6 shows an internal structure of the heating pot 50. A pot mainbody 51 of the heating pot 50 has a cylindrical (or generallycylindrical) shape having a circular cross-section, and is formed of,for example, stainless steel. In the internal area 55 of the heating pot50, the plurality of water steam ejection sections 52 (52A, 52B) arelocated. The water steam ejection sections 52 are formed of pipes(sparge pipes) having vapor (water steam) ejection openings located atan equal interval. The water steam ejection sections 52 are located inthe longitudinal direction of the cylindrical heating pot 50, so thatthe water steam 53 is ejected into the internal area 55 of the heatingpot 50 as uniformly as possible.

The pipes forming the water steam ejection sections 52 may extend so asto include a curved part, or extend in a meandering manner, instead ofextending straight in the longitudinal direction (or horizontaldirection). Alternatively, the pipes forming the water steam ejectionsections 52 may extend in a spiral manner in the internal area 55 of theheating pot 50, or a plurality of such pipes extending in acircumferential direction in the internal area 55 of the heating pot 50may be coupled to each other. Even in a structure in which the pipesforming the water steam ejection sections 52 extend straight, the watersteam 53 can be sprayed uniformly, but the spraying uniformity of thewater steam 53 can be possibly improved when the pipes extend to includea curved part, extend spirally, or extend to include a circular part.

In the structural example shown in FIG. 6, the pipes forming the watersteam ejection sections 52 are located so as to contact the inner wallof the heating pot 50. The structure of the pipes is not limited tothis. For example, the pipes may extend so as to pass through theinternal area 55 of the heating pot 50. The water steam ejectionsections 52 are not limited to having a form of pipe, and may be in anyother form. The water steam ejection sections 52 may be, for example,through-holes formed in the pot main body 51 of the heating pot 50,through which the water steam 53 can be ejected. Alternatively, thewater steam ejection sections 52 may be formed of sprinkler-like membersor disc-like members having a through-hole, from which the water steam53 can be ejected.

A pipe for supplying water (tap water or cooling water) may be connectedto the water steam ejection sections 52, so that water (cooling water)is sprayed from the water steam ejection sections 52. Such a waterspraying mechanism can act as a cooling mechanism of the heating pot 50.The water spraying mechanism may have the following structure, forexample. A switch valve and a water pipe are attached to a part of thewater steam supply pipe 12 connected to the water steam ejectionsections 52, so that tap water (or any other type of water) can beintroduced by switching the switch valve. In this manner, the coolingmechanism can be provided by a simple structure. Instead of allowingwater to flow in the water steam ejection sections 52, an independentcooling water pipe (sparge pipe) may be located, so that water (coolingwater) can be sprayed into the heating pot 50. Alternatively, asprinkler device may be located. In the example shown in FIG. 6, anopening (connection end) 69 b of the discharge pipe 69 is shown. Sprayedcooling water or the like can be discharged through the opening 69 b ofthe discharge pipe 69.

In addition, the liquid pot main body 21 included in the liquidcontainer 20 shown in FIG. 6 has a rectangular (or parallelepiped)shape, but the shape of the liquid pot main body 21 is not limited tothis. For example, the liquid pot main body 21 may have a cylindricalshape having the opening 21 a in the upper part thereof or a polygonalshape. In the structural example shown in FIG. 6, a top end of theliquid pot main body 21 projects from the inner wall of the heating pot50, but the liquid pot main body 21 is not limited to this. The top endof the liquid pot main body 21 may be flush with the inner wall of theheating pot 50.

A top lid which covers, but does not seal, the top opening 21 a of theliquid pot main body 21 may be located. This top lid can prevent rubbishor foreign objects from entering the internal area 55 of the heating pot50. Instead of the top lid, a porous member formed of an air-permeablemesh-like or net-like member may be located so as to cover the topopening 21 a of the liquid pot main body 21.

FIG. 7A and FIG. 7B are respectively a front view and a side view(cross-sectional view) showing a structure of the heating pot 50 in thisembodiment. As shown in FIG. 7A, a door 57 (57A) for closing a frontopening of the pot main body 51 of the heating pot 50 is provided on thefront side thereof. The door 57 is openable/closable by hinges 58, andcan be locked by a lever 59. In this structural example, as shown inFIG. 7B, a door 57 (57B) for closing a rear opening of the pot main body51 of the heating pot 50 is provided on the rear side thereof. Theheating pot 50 having openable/closable doors 57A and 57B on the frontand rear sides thereof allows a heating target to be put into, or takenout of, the heating pot 50 through both of the front and rear doors.This can improve the work efficiency of the production line. Needless tosay, the heating pot 50 may have one openable/closable door (e.g., door57A) through which food (retort food) may be put into, or taken out of,the heating pot 50.

As shown in FIG. 7B, air discharge valves 60 a (60) are provided on anupper part (especially, on a highest part) of the heating pot 50. Inthis example, a plurality of discharge valves 60 are provided on theheating pot 50, so that air can be discharged from the heating pot 50 asuniformly as possible. In this embodiment, there is no specificlimitation on the structure or the type of the air discharge valves 60,and any valve which can appropriately discharge air (and/or internalvapor) while keeping the internal area 55 of the heating pot 50 in apressurized state (air vent) is usable. For example, as the dischargevalve 60 for discharging air from the device (pot), an automatic valve(automatic air vent) is preferable. For example, an air vent fordischarging air from a vapor pipe or a device (e.g., an air dischargevalve using the technology of thermostatic steam trap) is usable. Adevice for manually discharging air (and/or internal vapor) may beprovided. In this embodiment, in order to control the pressure of theinternal area 55 of the heating pot 50 positively and more precisely, anelectromagnetic relief valve may be provided, so that the internalpressure of the heating pot 50 can be adjusted. In the example shown inFIG. 7B, the air discharge valves 60 a are provided on the highest partof the heating pot 50. It is not absolutely necessary that the airdischarge valves 60 a are provided on the highest part, and there is nospecific problem as long as the air discharge valves 60 a are providedon the upper part. Relief valves 60 and 69 may be provided on both ofthe upper part and the lower part of the heating pot 50. On the upperpart, the air discharge valve 60 for discharging air (and/or internalvapor) may be provided; and on the lower part, a drain or the dischargepipe 69 for discharging the internal vapor may be provided. Through thedischarge pipe 69, gas (air and/or water vapor) in the heating pot 50can be discharged by adjusting the valve (variable valve 69 a).

In FIG. 7B, safety valves 61 are also provided on the upper part(especially, the uppermost part) of the heating pot 50. In the casewhere a sealed container having a high internal pressure is heated, asafety valve prevents from the internal pressure from becomingexcessively high and thus prevents the container from being broken.Since the retort sterilization device 100 in this embodiment uses thewater steam 53, which is minute-pressure vapor, the risk that theinternal pressure is raised to break the heating pot 50 is quite low,but the safety valves 61 are provided for safety. The internal pressureof the heating pot 50 can also be decreased by opening or closing thedischarge pipe 69 using the variable valve 69 a.

In this example, top lids 29 for covering the top openings 21 a of theliquid pot main bodies 21 included in the liquid containers 20 areshown. Each of the top lids 29 is located so as to cover, but not toseal, the liquid pot main body 21. The pot main body 51 of the heatingpot 50 is supported by support rods (support table) 65, and securingmembers 51 a for securing the support rods 65 are formed in an outercircumferential surface of the pot main body 51 of the heating pot 50.In the pot main body 51 of the heating pot 50, through-holes 12 cthrough which the water steam supply pipes (vapor supply pipes) 12extend from outside to the inside of the pot main body 51 are formed. Inthe heating pot 50, various sensors (temperature sensor, pressuresensor, etc.) are located. The sensors are connected to a control device(control board) for controlling the driving of the retort sterilizationdevice 100. According to the structure of this embodiment, the controldevice is used to adjust the internal pressure by use of an electricproportional valves located on the upper part or on each of the upperpart and the lower part of the heating pot 50, and also to control theboiler vapor to be taken into the heat exchanger 90. In this manner,both of the internal temperature and the internal pressure of theheating pot 50 can be adjusted. A proportional valve (proportionalcontrol valve or electromagnetic proportional control valve) can controla fluid in a proportional manner in addition to being controlled to beopened or closed. By changing a control signal to be sent to theproportional valve (proportional control valve), the flow rate of theflowing fluid can be continuously controlled in the range of 0 to 100%with respect to the maximum flow rate.

FIG. 7A and FIG. 7B do not show the heat exchanger 90, but at least oneheat exchanger 90 is provided for one heating pot 50. In thisembodiment, a plurality of (e.g., three) heat exchangers 90 are providedfor one heating pot 50, so that a large amount of water steam 53 can besupplied to the heating pot 50 as uniformly as possible, although thenumber of the heat exchangers 90 depends on the size and volume of theheating pot 50. The size of the heating pot 50 is, for example, asfollows, although there is no specific limitation thereon. The diameterof the heating pot 50 is, for example, 50 cm to 2 m or greater, and thelength of the heating pot 50 in the longitudinal direction is, forexample, 50 cm to 10 m or greater.

FIG. 8 shows a structural example in which the liquid container 20attached to the heating pot 50 and the heat exchanger 90 are connectedto each other via the communicating tube 30. The communicating tube 30extending from the heat exchanger 90 is connected to the liquidcontainer 20, and the opening 21 a of the liquid container 20 is exposedto the internal area 55 of the heating pot 50. The communicating tube 30is coupled to a drain pipe 34 for discharging the liquid from theinternal area 55 of the heating pot 50, so that the waste liquid can bedischarged from the drain pipe 34 via an openable/closable valve 33. Inthe case where the discharge pipe 69 is connected to the heating pot 50,the drain pipe 34 may be connected to the discharge pipe 69. The supportrods 65 for supporting the heating pot 50 are coupled to a base 67.

FIG. 9 shows a structural example of the heating pot 50, the water steamsupply pipes 12 (12A, 12B), and the water steam ejection sections 52(52A, 52B). In the example shown in FIG. 9, the one, common water steamsupply pipe 12 is branched into a first water steam supply pipe 12A anda second water steam supply pipe 12B, which are introduced into theinternal area 55 of the heating pot 50. In the example shown in FIG. 9,the first water steam supply pipe 12A and the second water steam supplypipe 12B are each branched into a plurality of (two) pipes. One of thefirst water steam supply pipes 12A extends so as to stride over theheating pot 50. The first water steam supply pipes 12A are not limitedto having this structure, and one of the first water steam supply pipes12A may extend below the heating pot 50.

A heating device 40 for heating the water steam may be provided in apart of the water steam supply pipes 12. In the case where the heatingdevice 40 is located in a part of the water steam supply pipes 12, thetemperature of the water stream flowing in the water steam supply pipes12 can be raised. Specifically, the heating device 40 can act as anadditional means (heating means) for adjusting the temperature in theretort sterilization device 100 to a predetermined level. The heatingdevice 40 is, for example, an electric heater. The electric heater 40 inthis embodiment is, for example, an electric heater of about severalkilowatts (e.g., plug heater, flange heater, etc.)

By heating the water steam by use of the heating device 40, overheatedwater steam can be generated from the water steam. When usualhigh-temperature, high-pressure boiler vapor is heated by an electricheater, the heating efficiency is not high because the flow rate of theboiler vapor is high. According to the structure of this embodiment,water vapor (minute-pressure vapor) having a low flow rate is heated bythe heating device (e.g., electric heater). Therefore, the overheatedvapor can be generated at a high efficiency. In an atmosphere of theoverheated vapor of the heating pot 50, food can be retort-heated(retort-sterilized) or heated. In the heating device 40, heating isperformed at substantially the same internal pressure as the atmosphericpressure (e.g., internal pressure of 1.2 atmospheric pressure or less)during the operation. Therefore, a safe operation in terms of thepressure can be guaranteed.

Now, with reference to FIG. 10, operation results of the retortsterilization device 100 in this embodiment will be described. FIG. 10is a graph showing the results of the operation of the retortsterilization device 100. The graph of FIG. 10 shows the temperature ofthe internal area 55 of the heating pot 50 (in a right part and a leftpart in the heating pot 50) and the core temperature of the food 70located therein (in a right part and a left part in the heating pot 50),and also shows the pressure of the internal area 55 in the heating pot50. In this example, the results of the operation of heating bottledfood are shown. One graduation of the horizontal axis is about 4minutes. In this example, water steam having an absolute pressure of0.12 MPaA or less (e.g., about 0.11 MPaA) is continuously introduced,and the pressure is raised by accumulating the pressure of the watersteam continuously added (zone T1). After the pressure reaches apredetermined level (0.20 MPaA), the internal pressure is controlled tobe constant at the level (zone T2).

When the retort sterilization device 100 starts operating, the internalpressure is raised. Along with this, the temperature in the heating pot50 is raised. It is seen that at the time of start and while thetemperature is rising (zone T1), the temperature difference betweenparts (right part, left part) in the heating pot 50, which would beusually large, is suppressed small. Namely, it is seen that thetemperature in the heating pot 50 is controlled with high uniformity. Itis also seen that while the temperature in the furnace is adjusted tothe set temperature (about 120° C.) (zone T2), the temperaturedifference between the parts (right part, left part) in the heating pot50 is very small. Along with the temperature rise in the heating pot 50,the core temperature of the food (right part, left part) also rises.Since the dispersion in the temperature between the parts in the heatingpot 50 (right part, left part) is very small, the dispersion in the coretemperature of the food is also very small. Since the core temperaturerises smoothly along with the temperature rise in the furnace, veryappropriate heating treatment can be performed. Owing to this, food canbe processed (heat-treated) to be tasty.

When the heating of the retort sterilization is finished, the internaltemperature is controlled to be decreased (point T3). Along with this,the temperature in the furnace and the core temperature of the food aredecreased. During the process of decreasing the internal temperature,pressurized air is introduced into the heating pot 50 by a compressorand the air is kept pressurized in the furnace until the coretemperature of the product is decreased to a certain temperature (e.g.,70° C.), in order to prevent the bag from being broken. In a final step,the internal pressure of the heating pot 50 is made the atmosphericpressure and the heated product is taken out. Thus, the retortsterilization treatment is finished.

As can be seen from FIG. 10, according to the retort sterilizationdevice 100 in this embodiment, the pressure and the temperature in theheating pot can be controlled precisely. A conceivable reason why suchprecise control can be performed is that since a minute pressure (e.g.,0.12 MPaA or less) is repeatedly added by the water steam to thepressure in the heating pot 50, the pressure, temperature, specificvolume, and amount of heat (latent heat) of the internal area 55 of theheating pot 50 do not change much. There is also the followingadvantage. Since the water steam has a low flow rate, the introductionof the water steam does not disturb the air in the internal area 55 ofthe heating pot 50, and the air can be smoothly released by the airdischarge valve 60 (or the discharge pipe 69) provided on the heatingpot 50.

By contrast, when the system of directly putting boiler vapor into theheating pot is used, at the time of making settings on the controldevice, the temperature and the pressure can each be regulated to apredetermined value. However, it is actually very difficult to removethe dispersion in the pressure and the temperature between parts in theheating pot. This will be described in more detail. With the system ofdirectly putting boiler vapor, when boiler vapor having a pressure of0.3 MPaA flows in (usually, boiler having a pressure of about 0.4 MPaAis used), namely, when the boiler is put into the heating pot from thepipe, the pressure of the vapor temporarily changes, for example, from0.3 MPaA to 0.1 MPaA. The temperature of the vapor changes from 133° C.to 100° C. The specific volume changes from 0.605 m³/kg to 1.673 m³/kg.The amount of heat (latent heat) changes from 516.8 kcal/kg to 539.6kcal/kg. It is very difficult to control the heating temperature using athermal medium (boiler vapor) having characteristics which changesignificantly when being put into the heating pot from the pipe. Inorder to continuously put boiler vapor as an external thermal source,the thermal source needs to have a pressure higher than the setpressure. This is also a factor of restriction. With the system ofdirectly putting boiler vapor, boiler vapor having a pressure of 0.3MPaA (133° C.) flows in. Therefore, the difference between thetemperature in the heating pot and the core temperature of the productis 100° C. or higher when the temperature starts rising. Thetemperatures of an area contacting the boiler vapor and an area notcontacting the boiler vapor keep rising while having a large temperaturedifference. When the core temperature of the product becomes about 110°C., the temperature starts rising proportionally. However, thetemperature difference is still about 13° C. (the temperature of theboiler vapor is 133° C., whereas the set temperature for the product is120° C.), and therefore there is a problem that the production qualityis not constant.

The system of directly putting boiler vapor into the heating pot has thefollowing problem. The conditions for the boiler vapor are changedsignificantly. Therefore, in the state where vapor having a pressurehigher than the set pressure and a temperature higher than the settemperature flows in, a rapid pressure decrease or a rapid temperaturedecrease may occur in the heating pot (in the furnace). Against such astate, it is needed to maintain the set temperature. In such a state,precise temperature control is almost impossible even if the flow rateof the boiler vapor is controlled by an electromagnetic valve. As aresult, the temperature non-uniformity occurs. Since the vapor having atemperature higher than the set temperature is present, the food ispartially burned or overdone. This promotes denaturing of protein, whichleads to poor taste or odor.

Similarly, with the system of putting hydroheat into the heating pot byuse of compressed air, at the time of making settings on the controldevice, the temperature and the pressure can each be regulated to apredetermined value. However, it is actually very difficult to removethe dispersion in the pressure and the temperature between parts in theheating pot. Both of the systems use a pressurized boiler vapor orcompressed air, and therefore have more serious problems in terms ofdriving safety and control on the temperature and the pressure than thesystem of this embodiment which uses minute-pressure vapor (watersteam).

With the system of directly putting boiler vapor into the heating pot, astrong alkaline boiler compound (e.g., of about pH 11 to 13) is usedwhen the boiler vapor is generated. Therefore, the strong alkalinecomponent may be mixed into the boiler vapor and attached to the bag ofthe product or the like. By contrast, according to the structure of thisembodiment, water steam obtained by boiling water by heat exchange isintroduced into the heating pot 50. Therefore, the problem of corrosionby such a strong alkaline component can be avoided.

With the system of putting hydroheat into the heating pot by use ofcompressed air, the compressed air needs to be introduced and thepressure of the air needs to be returned to the atmospheric pressureeach time. This involves a problem of poor energy efficiency. Inaddition, hydroheat drops below the heating pot because of the gravity,and thus it is necessary to keep supplying new hydroheat to the heatingpot and keep spraying the hydroheat to the food (retort food). This alsodecreases the energy efficiency. According to the technique of theembodiment of the present invention, water steam drifts in the heatingpot 50, and therefore is highly advantageous as compared with the systemwhich requires constant spraying of hydroheat to the food. According tothe technique of the embodiment of the present invention, thetemperature and the pressure can be raised by continuously supplyingwater steam acting as a heating source. Therefore, it is not necessaryto use compressed air, and also introduction of air acting as a heatinsulator can be avoided. This is also a great contributiontechnologically.

Therefore, according to the structure of this embodiment, the retortsterilization device (heating device) 100 having a high energyefficiency and/or capable of suppressing heating non-uniformly can berealized.

In the above embodiment, the retort sterilization device 100 capable ofperforming retort sterilization by use of water steam has beendescribed. By modifying the retort sterilization device 100 in thisembodiment, a hydroheat circulation-system retort sterilization device(heating device) can be realized.

FIG. 11 schematically shows a structure of a retort sterilization device200 in an embodiment according to the present invention. The retortsterilization device 200 shown in FIG. 11 has substantially the samebasic structure as that of the retort sterilization device 100 shown inFIG. 5. According to the retort sterilization device 200 in thisembodiment, heating water (hydroheat or warm water) can be circulatedthrough the heat exchanger (hydroheat generation device) 90, the heatingpot 50, and the communicating tube 30.

The communicating tube 30 of the retort sterilization device 200includes a second path 32 b separately from a first path 32 a. In thesecond path 32 b, a circulation pump 35 for circulating liquid(hydroheat) 25 is provided. Namely, the communicating tube 30 includesthe second path 32 b branched from the first path 32 a used as thecommunicating tube 30 for uniformizing the water level. According tothis structure, when the circulation pump 35 is operated in the statewhere an openable/closable valve 31 c of the first path 32 a is closedwhile openable/closable valves 31 a and 31 b of the second path 32 b areopened, the liquid (hydroheat) 25 can be circulated.

Specifically, when the water steam ejection sections (in this example,hydroheat ejection sections) 52 (in this example, 52A) are filled withthe liquid 25 (25 c) up to an upper part thereof, the liquid 25 (25 b)is heated by heat exchange performed by the heat exchanger 90 and thusbecomes high-temperature hydroheat 18. The hydroheat 18 flows in thewater steam supply pipes (in this example, hydroheat supply pipes) 12and is supplied as hydroheat 54 to the internal area 55 of the heatingpot 50 from the water steam ejection sections (in this example,hydroheat ejection sections) 52. Next, the liquid 25 c in the internalarea 55 of the heating pot 50 flows in the liquid container 20 (liquidpot main body 21) and enters the communicating tube 30. Then, the liquid25 a is circulated by the circulation pump 35.

According to the retort sterilization device 200 in this embodiment,heating is performed with hydroheat. Therefore, the heat transmissionefficiency is still improved as compared with heating with water steam.In the case where the pressure in the heating pot 50 is high, hydroheatheating treatment at a temperature exceeding 100° C. can be performed.As shown in FIG. 11, in the case where, for example, half or more of theinternal area 55 of the heating pot 50 is filled with hydroheat 25 (25c), the food (retort food) can be entirely heated and thus the heatingnon-uniformity does not occur. The temperature of the hydroheat can beadjusted in the range from a low temperature (room temperature to lessthan 100° C.) to a high temperature exceeding 100° C. In the case wherethe structure shown in FIG. 11 is applied to food which is notretort-packaged, a boiling step (stewing, boiling) with hydroheat can beperformed.

After the food is heat-treated by the retort sterilization device 200,the hydroheat 25 may be transferred to another tank to empty the heatingpot 50, and then the food (retort food) may be taken out. For performingheat treatment by the retort sterilization device 200 again, thehydroheat 25 may be introduced into the communicating tube 30 again fromthe another tank, so that the hydroheat 25 can be circulated in theretort sterilization device 200. After the hydroheat 25 is transferredto the another tank, heat treatment with water steam may be performed byswitching the openable/closable valves 31 a through 31 c, namely, byopening the openable/closable valve 31 a and closing theopenable/closable valves 31 b and 31 c.

According to the structure shown in FIG. 11, hydroheat may be circulatedin the state where the liquid level of the hydroheat (warm water) 25 ishigher than the top end of the liquid container 20 (liquid pot main body21) and lower than the position of the product (heating object). In thiscase, the hydroheat can be released like a shower from the sparge pipes(hydroheat ejection sections) 52 to perform heating with the shower. Inthe case where the heating pot 50 of the retort sterilization device 200in this embodiment is put into a pressurized state (by, for example,introducing compressed air), heating in a pressurized state can beperformed.

In FIG. 5 and the like referred to above, the liquid container 20(liquid pot main body 21) is located in the heating pot 50.Alternatively, as shown in FIG. 1, the liquid container 20 (liquid potmain body 21) may be located outside the heating pot 50. FIG. 12 is astructural view of the retort sterilization device 100 in which theliquid container 20 is located outside the heating pot 50.

In the retort sterilization device 100 shown in FIG. 12, a plurality ofwater steam ejection sections (sparge pipes) 52 (52A, 52B) are locatedin the heating pot 50. Also in the heating pot 50, a cooling water pipe(sparge pipe) 53 for ejecting cooling water is located. The coolingwater pipe 53 is connected to a cooling water supply pipe (e.g., waterpipe) 64 via through-holes 12 d. The heating pot 50 is provided with theair discharge valve 60 for discharging air, the safety valves 61, apressure adjustment valve (vacuum adjustment valve) 62 for adjusting theinternal pressure of the heating pot 50, a pressure sensor 63 a, a boostgauge 63 b. temperature sensors 63 c, core temperature sensors 63 d andthe like. Wiring lines for the core temperature sensors 63 d areconnected through through-holes 12 e. On the lower part of the heatingpot 50, the discharge pipe 69 is located. An air introduction pipe 66for cooling air, introducing compressed air or the like is connected tothe heating pot 50.

In the example shown in the figure, the pot main body 51 of the heatingpot 50 is supported by the support rods (support table) 65. Wheels areattached to lower parts of the support rods 65. Therefore, the retortsterilization device 100 in this structural example can be moved to adesired position in a plant. As described above, minute-pressure vaporis introduced into the heating pot 50 by the water steam generationdevice 10 including the heat exchanger 90 and is circulated to raise thepressure and the temperature in a synchronous manner.

In the case where the liquid container 20 is provided outside theheating pot 50 as shown in FIG. 12, the existing heating pot 50 isusable, unlike in the case where the liquid container 20 is provided inthe heating pot 50 as shown in FIG. 5. This provides an advantage that aheating pot of an existing retort sterilization device can be modifiedinto the structure shown in FIG. 12. Since the existing heating pot isusable, there is an advantage that the production cost and facility costcan be suppressed. Even in the case where the liquid container 20 isprovided outside the heating pot 50, the system of circulating warmwater (hydroheat) as shown in FIG. 11 can be constructed byappropriately locating and connecting the pipes.

In FIG. 1 and FIG. 12 described above, the liquid container 20 isprovided outside the heating pot 50; and in FIG. 5 and the like, theliquid container 20 is provided in the heating pot 50. The method forraising the temperature and the pressure in the heating pot 50 usingwater steam is not limited to using the liquid container 20. Forexample, in FIG. 13, the communicating tube 30 is connected to theheating pot 50, and is also connected to the bottom end of the liquidpath 91 of the heat exchanger 90. By this system also, the pressure andthe temperature in the entire heating pot can be raised in a synchronousmanner while water steam (minute-pressure vapor) is circulated. As shownin FIG. 14, the liquid 25 may be located in the bottom part in theheating pot 50 and thus stored, instead of using the liquid container20. The systems shown in FIG. 13 and FIG. 14 are also usable for a heattreatment method using water steam, which includes the step ofgenerating water steam by the water steam generation device 10 includingthe heat exchanger 90, the step of introducing water steam 53 into theheating pot 50, and the step of introducing the liquid 25 present in thebottom part in the heating pot 50 into the heat exchanger 90. In thestep of heating by the heating pot 50, the water steam is circulatedbetween the heat exchanger 90 and the heating pot 50, so that theinternal area 55 of the heating pot 50 can be put into a pressurizedstate. The structure of the water steam ejection section 52, thedischarge valves 60 (60 a, 60 b) and the like may be optionally modifiedin a preferable manner, as described above.

In the above-described embodiments, heat treatment of packaged food in apressurized state (retort sterilization treatment) has been mainlydescribed. The technique in this embodiment is not limited to this, andmay be usable for heat treatment of food which is not packaged and/orheat treatment other than retort sterilization treatment. This will bedescribed in more detail. When a conventional retort sterilizationdevice is used for usual heat treatment of food, if boiler vapor isdirectly sprayed to food which is not retort-packaged (e.g., fish, meat,etc.), the food may be non-preferably burned or may caused to smell likea boiler by a component contained in the boiler vapor (alkalinecomponent, etc.). In the system of spraying hydroheat at a highpressure, the food may be shredded due to the hydroheat, which is notpreferable. By contrast, heating with water steam performed by theheating device (retort sterilization device) 100 in this embodiment islike a streaming step performed in a basket steamer, because water steamis saturated water vapor. Therefore, the food can be prevented frombeing dried during the heating and can be heated in a preferable manner.In the case where the gauge pressure of the water steam is 0 kg/cm², theamount of latent heat is 539.6 kcal/kg. The amount of latent heat of thewater vapor is highest.

Food other than retort food can also be treated by the heating device100 in this embodiment. Examples of the food which can be treatedinclude frozen food (frozen fish, frozen meat, frozen vegetables, etc.),chilled food, seasoned food, dried food, and any other type of foodsuitable to the steaming step. Examples of the food which can be heatedby the heating device 100 in this embodiment include rice, root crops,fish, meat (including processed food such as ham and the like), bread,tea, coffee, “tsukudani” (food boiled down in soy sauce, etc.) and thelike. When frozen food or the like is heat-treated by the heating device100 in this embodiment, drips are generated from the frozen food.According to the structure of this embodiment, the drips can becollected in the liquid container 20 used for generating water steam. Inthe case where the drips have an odor and it is desired to avoid thefood from obtaining the odor, drips may be discharged through the drainpipe 34. Alternatively, the drips may be prevented from entering theliquid container 20 by the top lid 29. Still alternatively, the dripsmay be collected in an outer release pipe (another lower drain pipe) anddischarged by an electric proportional valve or a manual valve.

Recently, fish which can be eaten down to bones is a target ofattention. The heating device 100 in this embodiment performs heatingwith water steam, and therefore can easily produce a food product ofsuch fish which can be eaten down to bones. For example, in thestructure shown in FIG. 2, fish (e.g., frozen fish) 70 is put on thetrays 72 and is heated. By adding water vapor to the food (fish), fishwhich can be eaten down to bones can be produced. The fish may be givena flavor with a seasoning or may be kneaded and minced. There is nospecific limitation on the type of fish which can be heat-treated inthis embodiment. Low-cost small fish is given a high added value. It hasbeen confirmed that food heat-treated in this embodiment has very tasty.When fish having bones is heat-treated by the device in this embodiment,broiled fish which can be eaten down to bones can be provided. Examplesof fish which can be heat-treated in this embodiment includeblue-skinned fish such as mackerel, saurel, saury, sardine, and thelike. These types of fish may have a thick fat layer between theepidermis and the fish meat. In addition, flatfish, flounder,cutlassfish, yellowtail, herring and the like (including white-meatfish) may be used.

These types of fish can be used in the form of the entire body, in thestate where a part of the body such as an internal organ, head or thelike is removed, or in the state where the body is divided into parts.Parts with the bones, for example, the head, fins, backbone, littlebones and the like are preferably usable. In the market, fish withoutbones is sold. However, it is costly to completely remove the bones ofthe fish. In consideration of the reuse of resources, the problem ofgarbage and the like, it is technologically highly valuable that thebones of the fish are softened so as to be eatable by the heat-treatmentmethod or production method in this embodiment. This is also valuable interms of nutrition because the bones of fish contain a lot of calcium.In addition, the softening of the bones solves the problem that seniorcitizens or children have a fishbone stuck in the throat.

The fish usable in this embodiment may be raw or pre-treated. In thisembodiment, “raw fish” encompasses fish which has not been heat-treatedyet, for example, fish which is chilled, frozen, or partially frozenwithout being heat-treated. Pre-freezing fish and defrosted fish causesa problem in storage. Therefore, it is technologically significant thatfrozen fish can be put into the heating pot 50 in this embodiment in thefrozen state and made eatable down to the bones.

The “pre-treated fish” usable in this embodiment refers to fish treatedwith any of various known methods performed on raw fish, except forheat-treatment. More specifically, “pre-treatment” encompasses variouscooking methods and various processing methods performed on raw fish,and a part thereof. For example, “pre-treatment” encompassesimpregnation treatment of impregnating with oil, extract, soup, salt,miso, soy sauce or the like; drying or dehydration treatment;fermentation treatment; treatment of attaching salt, pepper, flour,starch, rice flour, sesame, poppy seed, green laver, or powder or flakeof any of other various types of food; treatment of providing any otherfood as filling; treatment of providing the brown color or cutting lineson the outer layer; and the like; and also a combination of two or moreof these. In this specification, the “heat treatment” means treatment ofdenaturing protein in the fish by heat.

In the above, fish is described. Heat treatment by water steam can bemade on meat (frozen meat, dried meat, processed meat such as ham andthe like) and vegetables. A novel heating system (heat treatment withsaturated water vapor), which cannot be performed by the conventionalsystem of directly spraying boiler vapor or the conventional system ofspraying hydroheat at a high pressure, can be carried out. Thus, a novelcooking method, a novel meal, and novel preserved food can be realized.

In the above embodiments, the liquid 25 has not been specificallydescribed. The liquid 25 is typically water, and may be, for example,tap water, mineral water, ion exchange water, distilled water, or purewater. In addition, in the case where the food 70 is not packaged in acontainer, a seasoning may be added to the liquid 25, and the food maybe heat-treated while being seasoned with water steam containing theseasoning.

In the structure in which the heating device 40 for heating water steamis provided in a part of the water steam supply pipes 12 (see FIG. 9),overheated vapor can be generated from the water steam. In the casewhere a plurality of heating devices 40 are directly coupled to eachother, overheated vapor having a higher temperature can be generated.

Since the water steam generated by the heat exchanger 90 is saturatedvapor (saturated water vapor), the overheated vapor introduced into theheating pot 50 is gas containing a large amount of moisture althoughhaving a high temperature. Therefore, the problem that when food isheated with overheated vapor generated as a result of heating watersteam (saturated vapor), moisture is removed from the food more thannecessary and the food becomes too dry can be suppressed. On this point,the overheated vapor generated by heating the water steam is differentfrom the overheated vapor generated by heating high-temperature,high-pressure steam vapor to a high temperature (overheated vaporgenerated from steam vapor having a high degree of drying). This causesa difference in the quality (taste, dried state) of the resultant bakedfish-processed product.

The overheated vapor has the following advantages. First, the overheatedvapor has a feature of having a very high thermal efficiency because theoverheated vapor is transmitted through convection and also throughradiation. The baked state of fish or meat provided by the overheatedvapor is equivalent to or higher than that provided by an open flame orgas. The overheated vapor is water vapor and thus is transmitted fastthrough convection, specifically by about 10 times faster than air. Theoverheated vapor has an original property of water vapor of beingcondensed when contacting a low-temperature substance and giving heat tothe substance at the time of contact to raise the temperature (coretemperature) of the substance, and also a property of heating asubstance like heating air. Therefore, food can be baked within a shorttime. In addition, since the core temperature of a product is raised ina short time, the baking non-uniformity between the surface and theinside of the heating target (fish, meat, etc.) can be reduced.

The overheated vapor is in an oxygen-free state (or in a state of havinga lower oxygen concentration than that of the atmosphere of theatmospheric pressure). Therefore, oxidation of fats and oils,destruction of vitamins and the like can be suppressed, and thus thepreservation state of the product can be improved. In addition, the foodis prevented from losing color. Water has a property of holding oil whenbeing vaporized. This property is usable as a deoiling effect.

Cooking with overheated vapor having such characteristics does notremove too much moisture of the food, and thus can prevent the surfaceof the food from being hardened (e.g., production yield is 85% orhigher) and bring out the taste of the food material. The overheatedvapor is especially suitable for baking meat, a meat-processed product,or a fish-processed product. Specifically, when being baked withoverheated vapor, meat, the meat-processed product, or thefish-processed product becomes more tasty and is softened. A reason forthis is that since the meat, the meat-processed product, or fish isbaked in a low oxygen state (or in a substantially oxygen-free statesuch that candlelight put into the heating pot 50 is extinguished), thefats and oils thereof are not oxidized and thus do not cause anuncomfortable odor of oil. Another reason is that since the temperatureof the fish rises quickly, baking is performed in a preferable manner.In addition, in the case where the food contains a seasoning, theseasoning is entwined with the particles of gas or vapor and thus easilypermeates into the fish meat. Thus, the fish becomes more tasty. In theheating pot 50, far infrared rays are generated because of the presenceof the overheated vapor. This also improves the effect of heating. Inthe case where the temperature of the overheated vapor is 300° C. to350° C. or greater, fish can be heated at a temperature far higher than200° C., which is the boiling point of the fats and oils of the fish.This is also why the fish is tasty. Examples of the meat and themeat-processed product include beef, pork, chicken, mutton, ham, baconand the like. The overheated vapor is not limited to being used formeat, fish and processed products thereof, and is also usableeffectively for heating vegetables and for roasting tea or coffee beans.

For the heating pot 50 in this embodiment, a plurality of heatingdevices (electric heaters) 40 may be connected in series, so thatoverheated vapor having a temperature of, for example, 300° C. to 400°C. or higher (e.g., 550° C.) may be generated and introduced. In thiscase also, the retort sterilization device 100 can be operated while theinternal pressure of the pipes is substantially the atmosphericpressure. Specifically, the retort sterilization device 100 can beoperated at an internal pressure of merely 0.12 MPaA or less at most.When the overheated vapor is used, the heating treatment is preferablyperformed with the internal pressure of the heating pot 50 being kept ata minute pressure (0.13 MPaA to 0.15 MPaA) without being raised much,while the vapor is discharged from the lower part of the heating pot 50.In order to perform heating to a high temperature of 300° C. to 400° C.or higher using the boiler, an operation pressure of several atmosphericpressure or higher is needed, needless to say.

A reason why the heating device 40 can be operated at substantially 1atmospheric pressure is that high-temperature overheated vapor can begenerated by heating the water stream, which is minute-pressure vapor.In accordance with the technological common knowledge, in order togenerate high-temperature gas, a high pressure is needed. However, when,for example, heat high-temperature, high-pressure boiler vapor is to beheated, it is actually difficult to heat the boiler vapor in asuccessful manner, or even if the boiler vapor is heated, aninefficiently huge amount of energy is required, because the flow rateof the boiler vapor is high. By contrast, according to the structure ofthis embodiment, water steam as the minute-pressure vapor drifts slowlyin the pipe path. Therefore, during this time period, the food can beheated by the electric heater. Overheated vapor of a high temperature(e.g., 300° C. or higher) can be generated at substantially theatmospheric pressure. In the case where the retort sterilization device100 is in a pressurized state, the overheated vapor is generated in thepressurized state.

The overheated vapor generated by the heating device 40 preferably has atemperature of 180° C. or higher. A reason for this is that theoverheated vapor generated by heating water steam (saturated vapor)changes properties thereof at about 180° C. and becomes suitable forheat treatment performed on food materials or the like. This will bedescribed in more detail. Overheated vapor generated by heatingsaturated vapor is very lightweight and easily fills an enclosed spacedown to corners thereof. The overheated vapor has a high rate ofexpansion, a low content of oxygen, and a high heat transmission rate.When a food material is heated using such overheated vapor, the surfacelayer of the food material can be burned. The overheated vapor permeatesinto the outer layer to raise the internal temperature thereof, and canvaporize only the moisture of the surface layer. As a result, the insideof the food material can be baked in a juicy state while the surface isbrowned to look delicious. The overheated vapor has a property ofchanging the temperature thereof rapidly by a small change of the amountof heat. Therefore, it is preferable for heat treatment of food thatoverheated vapor having a temperature of 180° C. or higher is generatedand introduced into the internal area 55 of the heating pot 50, asopposed to relatively unstable overheated vapor of about 120° C.

Now, with reference to FIG. 15, a production device (production system)300 of a fish-processed product including the heating device 100 in thisembodiment, and a method for producing the fish-processed product willbe described.

The production system 300 of a fish-processed product shown in FIG. 15includes the heating device 100 including the above-described heatingpot 50, a kneader 160 for kneading fish heated by the heating pot 50,and a high-temperature vapor baking machine 170 for baking the kneadedfish.

The heating pot 50 shown in FIG. 15 includes a cylindrical (or generallycylindrical) main body 51. The heating pot 50 in this example hasopenable/closable doors 57A and 57B respectively at a front opening anda rear opening of the pot main body 51. Therefore, referring to FIG. 15,the door 57A at the front opening is opened to put the fish into theheating pot 50 as represented by arrow 141 to perform the heating step,and after the heating step, the door 57B at the rear opening is openedto take out the heated fish as represented by arrow 142. The heating pot50 having the openable/closable doors 57A and 57B respectively at thefront side and the rear side can improve the work efficiency of theproduction line. Needless to say, the heating pot 50 may have oneopenable/closable door (e.g., door 57A) through which fish is put into,and taken out of, the heating pot 50.

In this example, in a lower part in the heating pot 50, a plate (flatplate) may be provided. On the plate, for example, a basket steamer(formed of a metal or plastic material; not shown) packed with aplurality of pieces of frozen fish (frozen saurel) is placed. Aplurality of basket steamers may be stacked on the plate. Alternatively,a plurality of basket steamers may be placed on the plate in parallel.Instead of the plate, a palette may be provided in the lower part in theheating pot 50. Below the plate, there is a opening for connecting theheating pot 50 and the communicating tube 30 directly or indirectly.

In this embodiment, a palette is packed with fish in a frozen state(e.g., frozen saurel) and is put into the heating pot 50 as representedby arrow 141 in FIG. 15. Then, the heating pot 50 of the heating device100 in this embodiment is heated for about 1 hour to soften the bones.Next, as represented by arrow 142, the door 57B is opened and the heatedpalette is taken out, and then the heated fish is put into the kneader160. In the kneader 160, the fish meat is kneaded with the softenedbones to provide minced fish. During (or before or after) the kneadingstep performed by the kneader 160, a seasoning (e.g., vegetable oil,amino acid, salt, etc.) is added to, and mixed with, the minced fish.The pre-treatment described above may be performed on this stage.

Next, the fish (fish-processed product) kneaded and then flaked is bakedby the high-temperature vapor baking machine 170. The high-temperaturevapor baking machine 170 shown in FIG. 15 is a device for heating vapor(water vapor) to generate overheated vapor and baking a heating target(kneaded fish) 165 with the overheated vapor. As described above, theoverheated vapor is vapor obtained by heating water vapor to atemperature exceeding 100° C. at a constant pressure. Unlike the watervapor or high-pressure, high-temperature water vapor, the overheatedwater vapor (or overheated vapor) is heat radiating gas for radiatingfar infrared rays suitable to heat food, and an atmosphere thereof hasan advantage of, for example, blocking oxygen and thus preventingoxidation. It is known that when overheated water vapor is used, fish,meat and the like can be, for example, baked to be tasty.

A high-temperature vapor baking machine using overheated vapor typicallyheats high-temperature, high-pressure boiler vapor by a baking deviceincluding a burner which provides a larger amount of heat (or ahigh-output electromagnetic heating device) to generate overheatedvapor, and uses the overheated vapor. However, such a machine does nothave a high energy efficiency. The high-temperature vapor baking machine170 in this embodiment heats water steam (minute-pressure vapor) by aheating device (e.g., electric heater) to generate overheated vapor, andsprays the overheated vapor to the heating target (kneaded fish) 165 tobake the kneaded fish 165.

The high-temperature vapor baking machine 170 shown in FIG. 15 will bedescribed more specifically. The high-temperature vapor baking machine170 includes a water steam generation device 180 for generating watersteam 161, and a heating device 172 for heating the water steam 161 togenerate overheated vapor 162 (or 175). The generated overheated vapor162 is introduced into a baking chamber 177 for baking the kneaded fish165. In the baking chamber 177, ejection pipes 174 for ejecting theoverheated vapor 175 are located.

The heating device 172 in this embodiment is, for example, an electricheater. In the example shown in FIG. 15, a plurality of heating devices172 a and 172 b are connected in series. One heating device 172 may beprovided, or three or more heating devices may be connected in series.The heating devices 172 may be located in parallel, instead of inseries, so that the overheated vapor 162 and 175 can be generated fromthe water steam 161. The water steam generation device 180 forgenerating the water steam 161 is connected to the heating device 172(172 a) via a water steam supply pipe 181. The heating device 172 (firstheating section 172 a) is connected to the heating device 172 (secondheating section 172 b) via a vapor pipe 182. The second heating section172 b is connected to the ejection pipes 174. The ejection pipes 174each have an ejection opening 176 at a tip thereof, through which theoverheated vapor 175 is ejected.

The high-temperature vapor baking machine 170 in this embodimentincludes a belt conveyor 185 passing through the baking chamber 177. Thebaking chamber 177 is an open space which is opened at an entrance andan exit for the belt conveyor 185. The ejection openings 176 of theejection pipes 174 are located above the belt conveyor 185. The bakingchamber 177 is formed of, for example, stainless steel. In thisembodiment, the ejection pipes 174, the vapor pipe 182, and the watersteam supply pipe 181 are also formed of stainless steel.

In this embodiment, the fish 165 kneaded by the kneader 160 is put onthe belt conveyor 185 as represented by arrow 143. The belt conveyor 185advances as represented by arrow 144, and the kneaded fish 165 is bakedin the baking chamber 177 with the overheated vapor 175. Then, alongwith the movement of the belt conveyor 185 represented by arrow 145, thebaked fish 165 comes out of the baking chamber 177 and flows downstreamas a baked product (fish-processed product). In the example shown here,the kneaded fish 165 is put on a metal (e.g., stainless steel) net in athin, spread state. The net having the thin, spread fish 165 is put onthe belt conveyor 185, and the fish 165 is baked with the overheatedvapor 175.

According to the production method in this embodiment, fish heated bythe heating pot 50 (fish softened to the bones) is kneaded, so that evenbones, head and fins are eatable without being disposed of. In the casewhere a seasoning is added during the kneading, adjustment of taste canbe omitted in a step thereafter (baking step) and thus the work ofproducing the fish-processed product flows well. The kneaded fish is puton the belt conveyor 185 as being spread to be thin (e.g., to athickness of about 1 cm to 5 cm) and thus can be baked with theoverheated vapor efficiently (since the fish is thin, heat istransmitted well and the fish can be baked uniformly). Instead of beingspread to be thin, the fish may be put into balls or blocks before beingbaked.

According to the high-temperature vapor baking machine 170 in thisembodiment, water steam as minute-pressure vapor drifts slowly in theheating device (electric heater) 172. Such water steam can be heatedefficiently by the electric heater 172 as compared with high-pressurevapor transferring at a high rate. As a result, the overheated vapor 175having a high temperature (e.g., 300° C. or higher) can be generated atthe atmospheric pressure. The high-temperature overheated vapor 175 canbe sprayed, while having the high-temperature, to the fish (heatingtarget) 165 on the belt conveyor 185 located right below. The heatingdevice 172 in this embodiment is, for example, an electric heater, andcan perform heating at substantially the same internal pressure as theatmospheric pressure (e.g., internal pressure of 1.2 atmosphericpressure or less) during operation.

As the water steam generation device 180 shown in FIG. 15, any devicefor generating water steam is usable with no specific limitation. It ispreferable that the water steam generation device 180 includes theabove-described heat exchanger 90 from the viewpoints of energyefficiency and continuous use. When, for example, the temperature of thewater steam generated by the water steam generation device 180 is about95° C. to 110° C., the water steam is generated by the electric heaters172 (172 a, 172 b) to become overheated vapor (superheated vapor) havinga temperature of 150° C. or higher, preferably 180° C. or higher (or300° C. to 600° C. or higher). The electric heater 172 in thisembodiment is, for example, of about several kilowatts (e.g., plugheater, flange heater, etc.).

Since the water steam 161 is saturated vapor (saturated water vapor),the overheated vapor introduced into the baking chamber 177 is gascontaining a large amount of moisture although having a hightemperature. Therefore, the problem that when food is heated withoverheated vapor generated as a result of heating water steam (saturatedvapor), moisture is removed from the food more than necessary and thefood becomes too dry can be suppressed. On this point, the overheatedvapor generated by heating the water steam is different from theoverheated vapor generated by heating high-temperature, high-pressuresteam vapor to a high temperature (overheated vapor generated from steamvapor). This causes a difference in the quality (taste, dried state) ofthe resultant baked fish-processed product.

The high-temperature vapor baking machine 170 in this embodiment cangenerate overheated vapor having a temperature of, for example, 300° C.to 400° C. or higher (e.g., 550° C.), but is operated at an internalpressure of substantially 1 atmospheric pressure. Specifically, thehigh-temperature vapor baking machine 170 is operated at 1.2 atmosphericpressure or less at most. In order to perform heating to a hightemperature of 300° C. to 400° C. or higher using the boiler, anoperation pressure of several atmospheric pressure or higher is needed,needless to say.

A reason why the high-temperature vapor baking machine 170 can beoperated at substantially 1 atmospheric pressure is thathigh-temperature overheated vapor can be generated by heating the waterstream, which is minute-pressure vapor. In accordance with thetechnological common knowledge, in order to generate high-temperaturegas, a high pressure is needed. However, when, for example,high-temperature, high-pressure boiler vapor is to be heated, it isactually difficult to heat the boiler vapor in a successful manner, oreven if the boiler vapor is heated, an inefficiently huge amount ofenergy is required, because the flow rate of the boiler vapor is high.By contrast, according to the structure of this embodiment, water steamas the minute-pressure vapor drifts slowly in the pipe path. Therefore,during this time period, the food can be heated by the electric heater.Overheated vapor of a high temperature (e.g., 300° C. or higher) can begenerated at the atmospheric pressure.

According to the high-temperature vapor baking machine 170 in thisembodiment, even though the baking chamber 177 is of an open type,frozen fish (frozen mackerel, etc.), for example, can be completelydefrosted and also baked within several minutes when the temperature ofthe overheated vapor is set to 300° to 400° C. (in a typical example,400° C.±10° C.) or 300° C. to 550° (in a typical example, 450° C±10°C.). Therefore, the fish 165 which has been heated and kneaded can bebaked successfully with the overheated vapor 175.

It is preferable that the temperature of the overheated vapor 175ejected from the ejection pipes 174 is 180° C. or higher. A reason forthis is that the overheated vapor generated by heating water steam(saturated vapor) changes properties thereof at about 180° C. andbecomes suitable for heat treatment performed on food materials or thelike. This will be described in more detail. Overheated vapor generatedby heating saturated vapor is very lightweight and easily fills anenclosed space down to corners thereof. The overheated vapor has a highrate of expansion, a low content of oxygen, and a high heat transmissionrate. When a food material is heated using such overheated vapor, thesurface layer of the food material can be burned. The overheated vaporpermeates into the outer layer to raise the internal temperaturethereof, and can vaporize only the moisture of the surface layer in alarge amount. As a result, the inside of the food material can be bakedin a juicy state while the surface is browned to look delicious. Theoverheated vapor has a property of changing the temperature thereofrapidly by a small change of the amount of heat. Therefore, it ispreferable for heat treatment of food that overheated vapor having atemperature of 180° C. or higher is generated and introduced into thebaking chamber 177, as opposed to relatively unstable overheated vaporof about 120° C.

In the example shown in FIG. 15, the ejection pipes 174 are insertedfrom above the baking chamber 177. The ejection pipes 174 are notlimited to this. For example, the ejection pipes 174 may be introducedfrom the side of the baking chamber 177 (left side, right side, or bothof the left side and the right side) such that the ejection openings 176of the ejection pipes 174 are located above the belt conveyor 185. Thereis no specific limitation on the number or positions of the ejectionpipes 174, which may be appropriately selected in accordance with thebaking conditions. The ejection pipes 174 and the ejection openings 176thereof may be located above and below the belt conveyor 185, so thatthe food is baked from both sides. The distance between the ejectionpipes 174 and the heating device (electric heater) 172 closest to theejection pipes 174 may be short. In this case, the overheated vapor 175can be sprayed to the fish (food) 165 while the temperature of theoverheated vapor 175 is prevented from decreasing.

The fish-processed product in this embodiment is usable in a wide rangeincluding ingredients of rice balls, ingredients of sandwiches,ingredients of fish-mixed rice, toppings of salad, ingredients of pastaand the like. When fish is eaten with bones, the calcium intake is tentimes higher than that when fish without bones is eaten. Therefore, fishwith bones is optimal as health food. The fish may be provided in thestate where the entire body including bones is treated, or as an IQF(Individual Quick Frozen) product with the bones being soften while theshape of the fish being kept. In the latter case, the product can beeaten with a taste of boiled fish. Slices of fish may be provided astempura. Tempura may be cooked by the high-temperature vapor bakingmachine 170 with the overheated vapor after oil is applied to thesurface of the fish, instead of being deep-fried with oil. Afish-processed product can be provided with the shape of broiled fish orboiled fish being left. For providing a fish-processed product with theshape of fish being left, the fish is merely heated by the heating pot50 of the heating device 100 (or, additionally baked by thehigh-temperature vapor baking machine 170) without being kneaded by thekneader 160.

The production method of a fish-processed product in this embodimentaccording to the present invention includes the step of heating fishhaving bones by the heating pot 50. In this embodiment, the productionmethod further includes the step of kneading the fish heated by theheating pot 50, and the step of baking the kneaded fish by thehigh-temperature vapor baking machine 170. In the step of heating, thetop end 91 a and the bottom end 91 b of the liquid path 91 of the heatexchanger 90 are connected to the heating pot 50 via the pipes 12 and 14respectively, and the water steam 15 is circulated between the heatexchanger 90 and the heating pot 50, so that the internal area 55 of theheating pot 50 is put into a pressurized state. Therefore, bycontinuously introducing the water steam into the heating pot 50 whilecirculating the water steam between the heat exchanger 90 and theheating pot 50, the fish located in the heating pot 50 can be heatedwhile being gradually pressurized. As a result, in the heating step, thebones of the fish can be softened.

According to International Publication WO2006/025102 proposing aproduction method of a fish-processed product which is softened down tothe bones, the step of decreasing the pressure is necessary. With theheating device 100 in this embodiment, such a step decreasing thepressure is not necessary, and thus significant energy loss can besuppressed. In the step of heating in a pressurized state, air forpressurization does not need to be introduced, and the step of heatingcan be performed by a heating pot which can be pressurized efficiently.In the step of heating, boiler vapor does not enter the heating pot.This provides advantages that there is no boiler vapor odor in theheating pot and the retort pouch does not smell like boiler vapor.

Since the fish (fish meat) with softened bones is kneaded and baked bythe high-temperature vapor baking machine 170, the bones, fins, head andthe like of the fish can be used without being disposed of. As describedabove, the calcium intake provided by a fish food product in which bonesare eatable is about ten times higher than that provided by a fish foodproduct with no bones. Thus, the technique in this embodiment decreasesthe amount of wastes and thus decreases the material cost, which ispreferable environmentally. The technique of this embodiment is alsopreferable for health in terms of calcium intake. Since the kneaded fishis baked by the high-temperature vapor baking machine 170, the fish ismore tasty. The high-temperature vapor baking machine 170 bakes in anoxygen-free state (e.g., at a temperature of 300° C. or higher).Therefore, the fat components of the fish baked by this machine is notoxidized and thus the fish does not have a fat odor, as opposed to thefish baked by a burner. Baking by the high-temperature vapor bakingmachine 170 also provides effects that the temperature of the fish israised quickly and that a seasoning is entwined with particles of gas orvapor and thus easily permeates into the fish meat to make the fish moretasty.

The heat treatment performed by the heating pot 50 of the heating device100 is suitable for fish having bones. Needless to say, a processedmarine product (and/or food product) with no bones can be heated by theheating pot 50 of the heating device 100. The heat treatment methodperformed by the heating pot 50 is usable for any type of food, not onlyfor fish, as a simple heat treatment method performed in a pressurizedstate. As described above, the range of uses of the heating device 100(or the heating pot 50) in this embodiment is wide. Monitoring wasconducted for obtaining general evaluation on products (fish-processedproducts) in this embodiment. Ten out of ten people evaluated theproducts very highly, and thus the tastiness of the products has beenproved.

So far, preferable embodiments of the present invention have beendescribed. The present invention is not limited to these embodiment, andcan be modified in various manners, needless to say. The features of thedevices shown in the figures can be combined appropriately, and eachfigure does not disclose only the structure of the device shown therein.For example, the water steam ejection section 52 located in an upperpart in the device shown in FIG. 14 is usable to a device shown inanother figure. The device shown in FIG. 14 may have the air dischargepipe 60 or the like.

According to the present invention, a retort sterilization device and aheating device having a high energy efficiency and/or capable ofsuppressing heating non-uniformity can be provided.

Description Of Reference Characters

-   10 Water steam generation device-   12 Water steam supply pipe-   15 Water steam-   18 High-temperature hydroheat-   20 Liquid container-   21 Liquid pot main body-   21 a Top opening (opening)-   22 Lid-   23 Water level adjustment member-   25 Liquid-   26 Pipe (water pipe)-   28 Coupling pipe-   29 Top lid-   30 Communicating tube-   31 a, 31 b, 31 c Openable/closable valve-   32 a First path-   32 b Second path-   33 Openable/closable valve-   34 Drain pipe-   35 Circulation pump-   40 Heating device (electric heater)-   50 Heating pot-   51 Pot main body-   51 a Securing member-   52 Water steam ejection section (sparge pipe)-   55 Internal area of the heating pot-   57 Door-   58 Hinge-   59 Lever-   60 Air discharge valve-   61 Safety valve-   62 Vacuum adjustment valve-   63 (63 a-63 d) Sensor-   65 Support rod-   66 Air introduction pipe-   67 Base-   69 Discharge pipe-   70 Heating target (retort food)-   72 Container (tray)-   75 Plate-   82 Boiler pipe-   84 Exhaust steam pipe-   90 Heat exchanger-   91 Liquid path-   92 Vapor path-   93 Outer casing-   94 Boiler-   100 Retort sterilization device (heating device)-   160 Kneader-   161 Water steam-   162 Overheated vapor-   165 Heating target (kneaded fish)-   170 High-temperature vapor baking machine-   172 Heating device (electric heater)-   174 Ejection pipe-   175 Overheated vapor-   176 Ejection opening-   177 Baking chamber-   180 Water steam generation device-   181 Water steam supply pipe-   182 Vapor pipe-   185 Belt conveyor-   200 Retort sterilization device-   220 Rail-   230 Wheel-   240 Movable table-   250 Retort food-   260 Tray-   270 Motor-   280 Crank mechanism-   285 Driving shaft-   290 Shaft sealing device-   300 Production device (production system)-   1000 Retort sterilization device

What is claimed is:
 1. A retort sterilization device for performing heatsterilization in a pressurized state, comprising: a heating pot foraccommodating retort food; and a water steam generation device forgenerating water steam which is minute-pressure vapor; wherein: theheating pot is connected to the water steam generation device; the watersteam generation device has a liquid path and a vapor path independentfrom each other, and includes a heat exchanger for performing heatexchange between liquid flowing in the liquid path and heating vaporflowing in the vapor path; the heating vapor from a boiler is introducedinto the vapor path of the heat exchanger; a top end of the liquid pathof the heat exchanger is connected via a water steam supply pipe to awater steam ejection section located in the heating pot; the heatexchanger is connected to the liquid container for storing the liquid tobe supplied to the heat exchanger; a bottom end of the liquid path ofthe heat exchanger is connected to the liquid container via acommunicating tube; the liquid container is coupled to the heating pot;and the heat exchanger, the liquid container, and the heating pot areconnected so as to form a sealed space.
 2. The retort sterilizationdevice of claim 1, wherein: the liquid is stored in the liquidcontainer; and a water level of the liquid in the liquid containermatches a water level of the liquid in the liquid path of the heatexchanger.
 3. The retort sterilization device of claim 1, wherein theliquid container is provided with a water level adjustment member foradjusting the water level of the liquid.
 4. The retort sterilizationdevice of claim 1, wherein the liquid container is connected to theheating pot via a coupling pipe.
 5. The retort sterilization device ofclaim 4, wherein: the liquid container includes a liquid pot main bodyhaving a top opening in an upper part thereof and a lid for sealing thetop opening of the liquid pot main body; the liquid pot main body is apressure-resistant container; a bottom part of the liquid pot main bodyis connected to the communicating tube; and the lid is connected to thecoupling pipe.
 6. The retort sterilization device of claim 1, wherein:the liquid container includes a liquid pot main body having a topopening in an upper part thereof; and the liquid pot main body isattached to the heating pot such that the top opening is located in theheating pot.
 7. The retort sterilization device of claim 6, wherein abottom surface of the liquid pot main body is connected to thecommunicating tube.
 8. The retort sterilization device of claim 6,wherein a top lid which does not seal the top opening is provided at thetop opening of the liquid pot main body.
 9. The retort sterilizationdevice of claim 1, wherein: the heating pot is cylindrical; and a plateon which a container for accommodating the retort food is to be placedis located in the heating pot.
 10. The retort sterilization device ofclaim 1, wherein the water steam ejection section is a sparge pipelocated so as to extend in a horizontal direction in the heating pot.11. The retort sterilization device of claim 1, wherein a plurality ofthe water steam ejection sections are located in the heating pot. 12.The retort sterilization device of claim 1, wherein the water steamejection section is located in a lower area in the heating pot.
 13. Theretort sterilization device of claim 12, wherein: at least two of thewater steam ejection sections are located in the lower area in theheating pot; and at least two of the water steam ejection sections arelocated in an area above the lower area in the heating pot.
 14. Theretort sterilization device of claim 1, wherein a lower part of theheating pot is connected to a discharge pipe for discharging gas in theheating pot to outside the heating pot.
 15. The retort sterilizationdevice of claim 14, wherein: the discharge pipe is connected to avariable valve for varying an opened/closed state of the discharge pipe;and the discharge pipe is capable of discharging drip water from abottom part of the heating pot.
 16. The retort sterilization device ofclaim 1, wherein the heating pot is provided with at least one of an airdischarge valve for discharging air in the heating pot to outside theheating pot and a proportional valve as a pressure relief valve foradjusting an internal pressure.
 17. The retort sterilization device ofclaim 16, wherein the air discharge valve is attached to a highest partof the heating pot.
 18. The retort sterilization device of claim 1,wherein a heating device for heating the water steam is provided at apart of the water steam supply pipe connected to the water steamejection section.
 19. The retort sterilization device of claim 18,wherein the heating device is an electric heater.
 20. The retortsterilization device of claim 1, wherein the retort sterilization deviceis a pressurization and heating device for circulating the water steamthrough the heat exchanger, the heating pot and the liquid container toput an internal area of the heating pot into a pressurized state. 21.The retort sterilization device of claim 1, wherein the water steamgenerated by the water steam generation device is saturated water vaporhaving a minute pressure of 0.12 MPaA or less.
 22. The retortsterilization device of claim 1, wherein a cooling water supply pipe isconnected to a part of the water steam supply pipe such that coolingwater is ejected from the water steam ejection section.
 23. The retortsterilization device of claim 1, wherein the communicating tube forproviding communication between the heat exchanger and the liquidcontainer is branched into a first path and a second path.
 24. Theretort sterilization device of claim 23, wherein a circulation pump forcirculating the liquid is located in the second path.